Battery Testing Apparatus with Integral Thermal Control
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Solution Overview
Problem
Current battery testing methods lack precise control over temperature variations, which affects the accurate assessment of electro-chemical battery cell performance, especially during charging and discharging cycles, as traditional climate-controlled chambers may not provide individualized and simultaneous control over multiple cells.
Innovation Solution
A modular battery testing apparatus with integrated thermal control, featuring a battery cycler that includes a baseplate with cell pockets, thermal control devices, thermistors, and a microcontroller to regulate temperature and electrical parameters, allowing for precise temperature control and simultaneous testing of multiple cells in a climate-controlled environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional climate-controlled chambers are used for battery testing, then temperature control is provided for the entire chamber, but precise individual temperature control for each battery cell is not achieved
Solution Approach 1:
The testing system is segmented into independent testing modules, where each module contains its own thermal control device and temperature sensors for individual battery cells. This segmentation enables precise individual temperature control while maintaining modular system architecture that manages complexity.
Solution Approach 2:
Each battery cell pocket is equipped with localized thermal control capabilities including heating elements and cooling devices. This local quality approach allows different temperature conditions to be applied to different cells simultaneously, achieving precise individual temperature control without requiring entire chamber control.
2Productivity
If multiple battery cells are tested simultaneously in a climate chamber, then testing efficiency is improved, but individualized temperature control for each cell is lost
Solution Approach 1:
The system divides multiple battery cells into separate testing modules, with each module capable of independent temperature control. This allows simultaneous testing of multiple cells (improving productivity) while each cell receives individualized temperature management (maintaining reliability).
Solution Approach 2:
Each testing module is designed as a universal unit that can accommodate different battery cell types and configurations while providing the same high-quality individualized temperature control. This multi-functionality enables simultaneous testing of diverse cells without compromising control reliability.
3Measurement precision
If thermal control devices are added to each cell pocket, then individual temperature control precision is improved, but device complexity and cost increase
Solution Approach 1:
Temperature measurement and control functions are segmented into dedicated sensors and actuators at each cell pocket level. Each module has its own temperature sensors, heating elements, and cooling devices, creating independent control loops that simplify the overall system architecture while achieving precise individual control.
Solution Approach 2:
Each thermal control module incorporates temperature sensors that provide real-time feedback to microcontrollers, which automatically adjust heating and cooling operations. This closed-loop feedback control achieves precise temperature regulation without requiring complex manual control systems.
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
Enables precise control over ambient temperature for individual battery cells, allowing for more accurate performance assessment and efficient testing of both primary and secondary battery cells, improving the reliability and efficiency of battery testing processes.
Implementation Method 1
at least one thermal control device configured to regulate thermal energy in one respective cell pocket
Implementation Method 2
a baseplate thermistor configured to detect temperature of the baseplate
Implementation Method 3
at least one thermal control device thermistor. Each thermal control device thermistor is configured to detect temperature of one respective thermal control device
Implementation Method 4
a cooling fan configured to generate an airflow across the baseplate to remove thermal energy from the baseplate
Data Source
AI summary
A battery testing apparatus includes a battery cycler configured to position a battery cell in a cell pocket defined by a baseplate. The apparatus additionally includes a thermal control device configured to regulate thermal energy in the cell pocket, a baseplate thermistor for detecting baseplate temperature, and thermal control device thermistor for detecting thermal control device temperature. The apparatus also includes a printed circuit board (PCB) in electric communication with the thermal control device thermistor. An electronic microcontroller, in electric communication with the baseplate thermistor and the PCB, is configured to regulate operation of the thermal control device based on data from the baseplate thermistor and the thermal control device thermistor. A main controller, in electronic communication with the microcontroller, is programmed to establish set values for baseplate temperature and battery cell reference current or voltage and regulate electrical input to the battery cell in accordance with the reference values.