Battery Module Coupling Unit for On-Cell Replacement
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Solution Overview
Problem
Current battery systems face challenges in reliability and availability due to series connections, where a single failed battery cell can cause the entire system to fail, and high capacitance requirements for voltage stabilization are costly and space-intensive, while parallel connections lead to equalizing currents and increased costs for high-reliability components.
Innovation Solution
A coupling unit with switchable inputs and outputs allows for decoupling and reconfiguration of battery cells, enabling individual cell failure isolation, reduced parallel connections, and integrated pulse-controlled inverter functionality, using semiconductor switches for efficient voltage management and fault detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If battery cells are connected in series to meet voltage requirements, then the output voltage increases, but the system reliability decreases because a single failed cell causes entire system failure
Solution Approach 1:
The patent divides the battery system into modular units, each containing series-connected battery cells. These modules can be independently managed and replaced. When a cell fails, only the affected module needs to be replaced rather than the entire battery system, thus maintaining high voltage through series connection while improving reliability through modular segmentation.
2Power
If additional battery cells are connected in parallel to increase maximum current, then the available power increases, but equalizing currents occur between cells with different capacities and voltages
Solution Approach 1:
The patent uses modular battery units that can be independently managed. By segmenting the battery system into separate modules, the patent reduces the extent of parallel connections between cells with different characteristics, thereby minimizing equalizing currents while still achieving the required current capacity through selective module configuration.
3Stability of the object's composition
If a large capacitance is provided in the intermediate DC circuit to stabilize voltage during switching, then the voltage stability improves, but the cost and space requirements increase significantly
Solution Approach 1:
The patent employs dynamic voltage management through modular battery units with individual control. Instead of relying on large static capacitors, the system dynamically adjusts voltage by selectively connecting or disconnecting battery modules, thereby achieving voltage stability during switching operations without requiring large-capacity capacitors that would increase cost and space.
4Object-affected harmful factors
If high-reliability components such as contactors are used to separate battery cells from terminals, then the safety improves, but the system cost increases significantly
Solution Approach 1:
The patent segments the battery system into modular units that can be independently disconnected. This segmentation allows for simpler, less expensive disconnect mechanisms at the module level rather than requiring high-reliability contactors for the entire battery system. The modular architecture inherently improves safety by isolating faults to individual modules while reducing overall system cost.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances battery system reliability and availability by allowing faulty cells to be replaced without system failure, reduces the need for high-capacity capacitors, and eliminates equalizing currents, thereby increasing service life and reducing costs.
Implementation Method 1
The coupling units 30 can likewise be operated in a pulse-controlled inverter manner, in which case the coupling units 30 provide phase-shifted sinusoidal voltages at their outputs 33, 34 in a pulse width modulation manner
Implementation Method 2
The capacitance of the capacitor 11 must be large enough to stabilize the voltage in the DC link for a period of time in which one of the switchable semiconductor valves is switched through
Data Source
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Figure 3~5
AI summary
The invention relates to a coupling unit (30) for a battery module (40), comprising a first input (31), a second input (32), a first output (33) and a second output (34). The coupling unit (30) is designed to connect the first input (31) to the first output (33) and the second input (32) to the second output (34), on a first control signal, and, on a second control signal, to separate the first input (31) from the first output (33) and the second input (32) from the second output (34), and to connect the first output (33) to the second output (34). The invention also relates to a battery module (40) comprising such a coupling unit (30) and at least one battery cell (41) mounted between the first input (31) and the second input (32) of the coupling unit (30). A first terminal (42) of the battery module (40) is connected to the first output (33) of the coupling unit (30), and a second terminal (43) of the battery module (40) is connected to the second output (34) of the coupling unit (30). The invention further relates to a battery comprising at least one battery module line (50), a battery module line (50) comprising a plurality of battery modules (40) mounted in series. The battery comprises a control unit designed to generate the first and the second control signal for the coupling units (30) and to transmit said signals to the coupling units (30).