Battery String Reconfiguration for Scalable Voltage Balancing
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Solution Overview
Problem
Existing rechargeable battery systems face inefficiencies and scalability issues in cell balancing, particularly in large megapacks, due to uneven ion flow, heat generation, and voltage imbalances caused by gas accumulation and reagent depletion, leading to time-consuming and inefficient balancing methods.
Innovation Solution
A dynamic configuration method that detects voltage divergence across battery units, reconfigures them using SPDT switches, resistors, capacitors, and inductors to achieve even voltage distribution, allowing for efficient balancing of battery packs or cells while in an idle or reduced mode, leveraging resistive, capacitive, and hybrid circuits to manage heat and current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If passive or active balancing methods are used with microcontrollers and power electronic switching circuits, then cell voltage balancing can be achieved, but the process becomes very time consuming and suffers from efficiency loss
Solution Approach 1:
The patent divides the battery system into multiple string groups that can be independently reconfigured. Instead of balancing individual cells sequentially, the system segments the battery into parallel string groups and dynamically switches between series and parallel configurations to enable simultaneous balancing across multiple cells, significantly reducing total balancing time
Solution Approach 2:
The patent employs dynamic reconfiguration of battery strings using switching circuits that can change the electrical topology from series to parallel and vice versa. This dynamic switching allows the system to adapt the configuration based on real-time voltage divergence detection, enabling faster balancing compared to static passive or active methods
2Reliability
If passive or active balancing methods are used, then cell voltage balancing can be achieved, but case loss in efficiency occurs
Solution Approach 1:
The patent enables cells to balance themselves by dynamically reconfiguring the electrical topology. When strings are switched to parallel configuration, voltage differences naturally drive current flow from higher voltage cells to lower voltage cells through the switching network, eliminating the need for external balancing circuits and reducing energy loss
Solution Approach 2:
The switching circuit acts as an intermediary that facilitates energy transfer between cells during balancing. By intelligently switching between series and parallel configurations, the system creates efficient current pathways that minimize resistive losses compared to traditional passive resistor-based balancing or active power electronic converters
3Reliability
If individual cells are balanced in smaller groups, then balancing can be performed, but the solution is not scalable to large megapacks
Solution Approach 1:
The patent segments the large battery system into multiple manageable string groups that can be independently controlled and reconfigured. This segmentation allows the same balancing topology to be applied recursively across different scales, from small battery packs to large megapacks, providing excellent scalability
Solution Approach 2:
The patent creates a universal balancing architecture where the same switching network and control logic can handle different battery configurations and sizes. The system can operate in various modes (series, parallel, or combinations) and scale from individual cell balancing to entire megapack balancing without requiring fundamentally different approaches
4Reliability
If battery units are reconfigured to balance voltage, then even voltage distribution is achieved, but manual disassembly would be required without automated switching
Solution Approach 1:
The patent replaces manual mechanical disassembly and reassembly operations with automated electronic switching circuits. The switching network can dynamically reconfigure battery strings between series and parallel connections through electronic control signals, eliminating the need for physical manual intervention while achieving the same voltage balancing objective
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 approach enables fast and efficient cell balancing at the pack level, reducing inefficiencies and heat generation, and is scalable to large systems by dynamically reconfiguring battery units to achieve balanced voltage distribution without manual disassembly.
Implementation Method 1
manages heat dissipation of the one or more resistors
Implementation Method 2
balancing voltage differences across the capacitors
Implementation Method 3
an inductor can be added in series to capacitor to reduce the inrush current
Data Source
AI summary
A method provides power from battery units by placing units with a predetermined variance in voltages in a first configuration; detecting a divergence in module voltages; if the divergence crosses a threshold, creating a new configuration of units to provide an even voltage distribution; and electrically rerouting the units to form the new configuration while the battery units are in an idle state or in a reduced mode of operation.