Series Battery Overcharge Detection via Voltage Distribution Analysis
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Solution Overview
Problem
Existing battery pack systems face challenges in detecting and mitigating exceptional charge states, particularly overcharge events, which can lead to thermal runaway due to voltage monitoring and balancing system malfunctions or insufficiencies, especially in series-connected lithium-ion batteries.
Innovation Solution
A microprocessor-implemented system for detecting charge imbalances and exceptional charge events in series-connected energy storage elements, utilizing multiple detection and response modalities to address overcharge and overdischarge risks, including stopping charging, bleeding charge, adjusting SOC targets, and thermal control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If voltage monitoring and balancing systems are used to ensure charge balance, then overcharge risk is reduced, but system complexity increases and detection precision may be insufficient for exceptional charge events
Solution Approach 1:
The system performs preliminary detection of exceptional charge events by comparing individual series element voltages against expected voltage distributions before overcharge conditions develop. This early detection mechanism identifies potential overcharge risks in advance, allowing preventive action before the condition becomes severe, thereby improving reliability without requiring complex real-time intervention systems.
Solution Approach 2:
The patent introduces an intermediary detection layer that operates between conventional voltage monitoring and actual overcharge events. This intermediary system uses statistical analysis of voltage distributions across series elements to identify exceptional charge states, serving as a mediator that enhances detection precision while maintaining manageable system complexity through software-based analysis rather than additional hardware.
2Measurement precision
If multiple detection modalities are implemented to identify exceptional charge events, then detection precision improves, but device complexity increases
Solution Approach 1:
The system implements a multi-functional detection approach where a single processing unit performs multiple detection functions: it monitors individual series element voltages, analyzes voltage distributions, compares against expected patterns, and identifies exceptional charge events. This universal detection system achieves high measurement precision through software-based multi-functionality rather than separate hardware systems, thereby improving detection precision while controlling device complexity.
Solution Approach 2:
The detection system utilizes parameter changes in voltage distribution patterns across series elements to identify exceptional charge events. By monitoring how voltage parameters deviate from expected distributions during charging, the system achieves precise detection of charge imbalances. This parameter-based detection approach enables high measurement precision through mathematical analysis of existing voltage data without requiring additional sensors or complex hardware modifications.
3Productivity
If conventional voltage monitoring is used to ensure charge balance, then charging efficiency is maintained, but detection of exceptional charge events becomes difficult
Solution Approach 1:
The system implements feedback mechanisms that continuously monitor individual series element voltages during charging and compare them against expected voltage distributions. This feedback loop provides real-time information about charge balance status, enabling the system to detect exceptional charge events while maintaining normal charging operations. The feedback approach allows concurrent charging efficiency and exception detection without significant productivity loss.
Solution Approach 2:
The patent replaces traditional mechanical voltage monitoring approaches with software-based statistical analysis of voltage distributions. Instead of relying solely on hardware voltage thresholds, the system uses computational methods to analyze voltage patterns across series elements and identify exceptional conditions. This substitution of mechanical monitoring with software analysis maintains charging efficiency while significantly improving the difficulty of detecting and measuring exceptional charge events.
Data Source
AI summary
A system and method for identifying and responding to exceptional charge events of series-connected energy storage elements can include: a first charge imbalance detection system monitoring, using the microprocessor, the energy storage system for a charge imbalance using a first detection modality, said first charge imbalance detection system initiating a reduction of said charge imbalance using a first response modality; a second charge imbalance detection system monitoring, using the microprocessor, the energy storage system for an exceptional charge event of a particular one battery element of the plurality of battery elements using a second detection modality different from said first detection modality; and a remediation system initiating a response to said exceptional charge event using a second response modality different from said first response modality, said response decreasing a risk associated with said exceptional charge event.