Modular Battery Energy Storage System Cell Balancing Control
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Solution Overview
Problem
Aging electrical infrastructures face challenges in managing increasing electrical energy demand, particularly during peak periods, and existing energy storage systems are not cost-effective or reliable enough to meet these demands, especially with the integration of renewable energy sources.
Innovation Solution
A modular, stackable battery energy storage unit with a control system that includes battery packs, a battery pack controller, and a battery pack operating system, which features a balancing module, ampere-hour monitor, and data collection for insurance rate determination, allowing for scalable energy storage and management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing energy storage systems are used to meet increasing electrical energy demand, then energy storage capacity is provided, but the systems are not cost-effective or reliable enough
Solution Approach 1:
The energy storage system is divided into modular battery packs that can be independently manufactured, tested, and assembled. Each module contains standardized components (battery cells, circuit boards, housing) that can be produced separately and combined to form complete storage units, reducing manufacturing complexity and cost while improving reliability through standardized interfaces and quality control
Solution Approach 2:
The battery pack design incorporates universal mounting interfaces, standardized electrical connections, and multi-functional circuit boards that can serve multiple purposes (monitoring, control, protection). This universality allows the same basic module to be used in different configurations and applications, reducing overall system cost and improving reliability through proven standardized components
2Reliability
If battery cells are used without balancing, then energy storage capacity is maximized, but cell voltage and state-of-charge imbalances reduce system reliability
Solution Approach 1:
The system incorporates voltage sensing circuitry that continuously monitors individual cell voltages and provides feedback to the control system. When imbalances are detected, the controller activates balancing circuits to redistribute charge among cells, ensuring reliable operation while using simple threshold-based control logic rather than complex algorithms
Solution Approach 2:
Passive balancing resistors are introduced as intermediary components between battery cells to equalize voltage imbalances. These resistors provide a simple, reliable mechanism for charge redistribution without requiring complex active control circuits, maintaining system reliability while minimizing added complexity
3Adaptability or versatility
If modular stackable battery units are implemented, then scalability is improved, but system complexity increases
Solution Approach 1:
The system is segmented into standardized battery modules with uniform dimensions, electrical interfaces, and mounting configurations. Each module can be independently manufactured and assembled in series or parallel configurations to achieve desired capacity and voltage ratings, enabling scalable deployment from small to large systems without increasing per-unit complexity
Solution Approach 2:
Multiple identical battery modules are combined using standardized mechanical and electrical interfaces to form larger storage systems. The modular architecture allows seamless scaling by simply adding more modules rather than redesigning the system, reducing overall complexity through repetition of proven standardized components
4Adaptability or versatility
If data collection for insurance rate determination is implemented, then additional value proposition is provided, but system complexity and data processing requirements increase
Solution Approach 1:
The existing monitoring and control circuitry is designed to collect operational data (temperature, voltage, current, state of charge) for multiple purposes including safety monitoring, performance optimization, and insurance rate determination. This multi-functional use of the same data collection infrastructure provides additional value without requiring separate dedicated sensing systems
Solution Approach 2:
The system automatically collects and transmits operational data without requiring external intervention or additional hardware. The control system leverages existing sensors and communication interfaces to generate insurance-relevant data streams, adding value through self-service data provision rather than requiring complex external data gathering infrastructure
Data Source
AI summary
Disclosed herein are embodiments of an electrical energy storage unit, a control system, and applications thereof. In an embodiment, the electrical energy storage unit (which may also be referred to as a battery energy storage system (“BESS”) includes a battery system controller and a plurality of battery packs. Each battery pack of the plurality of battery packs has a plurality of battery cells, a battery pack controller that monitors the plurality of battery cells, a battery pack cell balancer that adjusts an amount of energy stored in each battery cell of the plurality of battery cells, and a battery pack charger. The battery pack controller operates the battery pack cell balancer and the battery pack charger to control a state-of-charge of each battery cell of the plurality of battery cells. In an embodiment, the battery cells are lithium ion battery cells.