Battery-Inverter Architecture Without DC/DC Boost Conversion
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Solution Overview
Problem
The use of DC/DC converters increases costs, and without them, high DC output voltages are required, leading to increased battery cell counts and costs, while existing systems without converters face challenges in insulation and voltage management.
Innovation Solution
An electrical storage device with a battery module and DC/AC inverter configuration that includes a switching unit, voltage detection, and control units to manage battery cell connections and voltages, using reused battery cells and omitting DC/DC converters to reduce costs and prevent overvoltage/overcurrent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If DC/DC converters are used to step up battery voltage, then the required number of battery cells is reduced, but the device cost increases
Solution Approach 1:
The patent removes the DC/DC converter from the system architecture, extracting this component that causes cost increase. Instead of using a DC/DC converter to step up voltage, the system directly connects the battery module output to the inverter, accepting the trade-off of requiring more battery cells in exchange for eliminating the converter and reducing overall device cost.
Solution Approach 2:
The patent changes the voltage parameter management approach by eliminating intermediate voltage conversion. The battery module operates at its native voltage level without DC/DC conversion, and the inverter directly converts this DC voltage to AC output. This parameter change in the voltage conversion pathway reduces component count and cost despite requiring more battery cells to achieve the necessary output voltage.
2Ease of manufacture
If DC/DC converters are omitted to reduce cost, then device cost decreases, but high voltage requirements increase the number of battery cells needed
Solution Approach 1:
The patent merges the voltage conversion function directly into the inverter unit, eliminating the separate DC/DC converter stage. The battery module connects directly to the inverter, which handles both the DC input and AC output conversion in one integrated unit. This merging reduces component count and cost while managing the voltage requirements through the inverter's direct conversion capability.
Solution Approach 2:
The inverter is designed to perform multiple functions: it accepts DC input from the battery module at various voltage levels and converts it to standardized AC output. This multi-functionality allows the system to operate without a DC/DC converter, as the inverter can directly handle the voltage conversion from the battery's native voltage to the required AC output voltage.
3Device complexity
If more battery cells are connected in series to achieve high voltage without DC/DC converter, then device complexity is reduced, but the risk of overvoltage and insulation issues increases
Solution Approach 1:
The patent implements feedback mechanisms through voltage detection units that continuously monitor the battery module output voltage and provide this information to the control unit. The control unit uses this feedback to dynamically adjust the switching unit's operation, ensuring that voltage remains within safe limits and preventing overvoltage conditions that could compromise insulation or system reliability.
Solution Approach 2:
The patent employs dynamic control through the switching unit, which can rapidly connect or disconnect battery cell groups in response to real-time voltage conditions. This dynamic adjustment capability allows the system to adapt to changing voltage levels, maintaining safety margins for insulation and preventing overvoltage damage while managing the high voltage requirements of the multi-cell configuration.
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
The solution enables a low-cost configuration with improved protection and efficient voltage management, allowing the use of inexpensive reused battery cells and preventing system failures.
Implementation Method 1
a DC/AC inverter configured to convert the DC voltage output from the battery module into an AC voltage
Data Source
AI summary
A device includes a battery module, and an inverter configured to convert a DC voltage output from the battery module into an AC voltage. The battery module includes battery cells connected in series, and a state detection unit configured to detect a state of each battery cell of the battery cells. An output voltage of the battery cells is input to the inverter without being stepped up. At least some battery cells of the battery cells are reused battery cells. The electrical storage device includes a switching unit configured to connect/disconnect an electrical connection between the battery cells and the inverter. The switching unit is controlled into a disconnected state when a voltage of the battery cells or the DC voltage on an input side of the inverter exceeds a threshold.