Battery Test Converter Layout With Switchable Booster Power
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Solution Overview
Problem
Existing battery testing systems are costly due to the need for transducers designed for maximum power ranges, which are only used for short periods, and coupling multiple converters for high power transfer complicates safety systems, increasing complexity and risk.
Innovation Solution
A testing system with a DC link, base and booster converters, safety switches, and a control unit that manages power transfer, allowing flexible power distribution and safety measures to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If transducers are designed for maximum power range to cover all test requirements, then power capability is improved, but cost increases significantly
Solution Approach 1:
The power conversion system is segmented into multiple base converters, each handling a specific test channel with moderate power requirements. This segmentation allows each converter to be optimized for lower power ratings, reducing individual converter costs while collectively meeting the total system power requirements through parallel operation.
Solution Approach 2:
The system dynamically switches between different converter configurations based on real-time power demands. The control unit monitors power requirements and activates additional base converters or the booster converter as needed, allowing the system to adapt its power delivery capability to match actual test requirements rather than maintaining maximum power capacity continuously.
2Power
If multiple converters are coupled to provide high power transfer, then power capability is improved, but system complexity and safety risk increase
Solution Approach 1:
Each base converter is designed with universal functionality to independently service any test channel. The converters connect to a common DC link and can be dynamically assigned to different test channels through switching mechanisms, allowing any converter to replace another if needed and simplifying the overall system architecture compared to dedicated converters for each channel.
Solution Approach 2:
A common DC link serves as an intermediary between the multiple base converters and the test channels. This DC link decouples the converters from direct one-to-one connections with test channels, allowing flexible power distribution and simplifying the control architecture. The DC link mediates power flow, enabling any converter to supply power to any channel through the common bus.
3Device complexity
If one-to-one coupling between transducer and test channel is used, then system simplicity is improved, but adaptability decreases
Solution Approach 1:
Each base converter is designed with slightly excessive power capacity relative to its assigned test channel, allowing the converter to handle peak power demands without requiring another converter. This partial over-capacity design provides headroom for transient high-power requirements while maintaining simple one-to-one coupling architecture.
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 reduces costs by optimizing power range usage and ensures safety without compromising on complexity, enabling efficient simultaneous testing of multiple batteries.
Implementation Method 1
electrical transducers are used to provide the necessary power transfer
Data Source
Figure 1
Figure 2
AI summary
A test system (10) for simultaneously testing a plurality of batteries, in particular high-voltage batteries, comprising: a DC link (22), a plurality of basic converters (1a-1h) that are connected to the DC link (22) and that are each connected to a test channel (4a-4h) via a connection line (24a-24h) in a switchable manner, a boost converter (2a, 2b) that is connected to the DC link (22) and that, during operation of the test system (10), is able to be connected to at least one of the test channels (4a-4h) via a booster line (26a, 26b) and a respective connecting node (18a-18h) on various ones of the connection lines (24a-24h), a control unit (27) for controlling the basic converters (1a-1h) and the boost converter (2a, 2b) according to a desired power transfer; wherein each connection line (24a-24h) has a safety-oriented switch (6a-6h) between test channel (4a-4h) and connecting node (18a-18h).