Configurable Battery Power Supply for DC-Link Pre-Charge
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Solution Overview
Problem
Existing power supply systems face challenges in accommodating varying operational constraints, power outputs, and communication attributes from different manufacturers, requiring custom-designed power electronics and control circuitry, which is costly, bulky, and time-consuming, especially when integrating new components like motors or batteries.
Innovation Solution
A configurable power supply system utilizing bi-directional DC-DC converters and contactors to pre-charge and power high voltage loads, allowing batteries to be connected in parallel or series configurations, with a predictive analytics process using machine learning to optimize power supply output characteristics, eliminating the need for new control circuitry and enabling automatic operation without external controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom-designed power electronics and control circuitry are used to accommodate different manufacturers' components, then the system can integrate diverse power components with varying operational constraints and power outputs, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent implements a universal power electronics platform that can accommodate multiple battery manufacturers and different power component specifications through a single standardized interface. The modular architecture allows the same power electronics to work with various battery chemistries, voltages, and power outputs without requiring custom design for each component combination, thereby reducing device complexity while maintaining adaptability.
Solution Approach 2:
The system employs configurable parameters within the power electronics and control circuitry that can be adjusted to match different manufacturers' operational constraints and power outputs. Rather than designing custom circuitry for each component, the platform uses parameter programming to adapt to varying specifications, reducing manufacturing complexity while maintaining versatility across different power components.
2Adaptability or versatility
If custom control circuitry is designed for each new component integration, then the system can accommodate new motors or batteries with different specifications, but the manufacturing time and development cost increase
Solution Approach 1:
The patent establishes a pre-configured power electronics platform with standardized interfaces and control algorithms that are prepared in advance to work with multiple manufacturers' components. This preliminary design work eliminates the need for custom circuitry development when integrating new motors or batteries, as the platform already contains the necessary adaptation capabilities, thereby significantly reducing integration time.
Solution Approach 2:
The universal power electronics platform is designed to handle multiple component types and specifications through a single standardized interface, allowing new motors or batteries to be integrated by configuring existing parameters rather than designing new control circuitry, thus reducing manufacturing time and development costs.
3Device complexity
If traditional power supply systems are used without modular configuration, then the system structure is simpler, but the ability to adapt to varying power specifications from different manufacturers is reduced
Solution Approach 1:
The patent divides the power supply system into modular segments including battery modules, power electronics modules, and control modules that can be independently configured and combined. This segmentation allows the system to maintain structural simplicity through standardized module interfaces while achieving adaptability by reconfiguring the modular components to match different power specifications from various manufacturers.
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 system provides a modular structure that adapts to varying specifications without requiring new control circuitry, reduces costs and complexity, and enables faster pre-charging while ensuring efficient power management and safety, thus addressing the challenges of integrating diverse power components.
Implementation Method 1
bi-directional DC-DC converters and contactors to pre-charge and power high voltage loads
Implementation Method 2
A configurable power supply system having one or more batteries configured to pre-charge and power a high voltage load
Implementation Method 3
pre-charge a DC-Link capacitor and power a high voltage load having the capacitor
Data Source
AI summary
A configurable power supply system that includes batteries, isolated bi-directional DC-DC converters, and contactors. Each battery has an isolated bi-directional DC-DC converter and contactors that are controlled in a sequence to pre-charge a DC-link capacitor and balance voltages of the batteries.