Battery Pack Simulator With Reconfigurable BMS and Cell Modules
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Solution Overview
Problem
The existing methods for inspecting battery packs are costly and inefficient, requiring frequent replacement of actual battery packs due to limitations in battery cell life and other factors, and there is a need for a simpler and cost-effective method to inspect multiple battery packs without producing individual simulators for each configuration.
Innovation Solution
A battery pack simulator that includes a plurality of BMS simulation units and cell simulation units, connected in series or parallel, with adjustable connections, capable of simulating various battery pack configurations and providing real-time data management and control, including SOH and SOC calculations, defect determination, and communication with an inspection device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If actual battery packs are used for inspection, then inspection accuracy is improved, but inspection costs increase and battery replacement frequency increases
Solution Approach 1:
The patent creates a virtual battery pack model that replicates the electrical characteristics and behavior of actual battery packs. This copy allows inspection devices to test against a simulated battery without consuming actual battery units, thereby maintaining inspection accuracy while eliminating the need for frequent battery replacements
Solution Approach 2:
The virtual battery pack simulator is designed to universally replace multiple actual battery packs across different inspection scenarios. A single simulator unit can serve the function of numerous actual batteries, allowing one inspection system to handle diverse battery inspection needs without requiring physical battery inventories
2Adaptability or versatility
If multiple battery pack configurations are inspected, then inspection versatility is improved, but device complexity increases
Solution Approach 1:
The virtual battery pack simulator employs dynamic reconfiguration capabilities where connection topologies (series, parallel, or combinations) can be programmatically adjusted without physical rewireting. This dynamic software-controlled configuration allows the system to adapt to various battery pack arrangements while maintaining a fixed physical hardware structure, thereby improving versatility without proportionally increasing complexity
3Measurement precision
If individual simulators are produced for each battery pack configuration, then simulation accuracy is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of manufacturing separate simulator hardware for each battery configuration, the patent implements a universal simulator platform that uses software programming to replicate different battery pack behaviors. This single multi-functional device can accurately simulate various series/parallel configurations through configurable parameters, eliminating the need for multiple specialized simulator productions
Solution Approach 2:
The simulator achieves different battery pack configurations by changing software parameters (such as connection topology settings, cell count, capacity values) rather than manufacturing different hardware units. This parameter-based reconfiguration maintains simulation accuracy across various battery types while keeping manufacturing complexity low, as only one hardware platform needs to be produced
Data Source
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AI summary
A battery pack simulator according to one embodiment of the present disclosure simulates a battery pack including a cell module assembly(CMA) including a plurality of battery cell stacks and a battery management system(BMS), and includes a plurality of BMS simulation units that simulate the BMS, wherein each BMS simulation unit manages and controls the state and operation of the battery pack to be simulated.