Battery Supply Voltage Staging for Narrow-Range Power Conversion
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Solution Overview
Problem
Conventional backup power systems face inefficiencies and high costs due to the need for semiconductor devices with non-optimal Figure of Merit (FOM) and high current handling, especially when dealing with high power loads and narrow voltage conversion ranges, which impacts efficiency, cost, and power density.
Innovation Solution
A power supply system utilizing a main battery source and auxiliary battery sources, controlled by a controller to adjust the battery supply voltage through serial connections and switch circuitry, optimizing voltage range and reducing power processing by the converter, thereby improving efficiency and reducing component size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional power converter topologies (buck, boost, 4-switch buck-boost) are used with semiconductor devices rated for total output voltage or input voltage, then the converter can handle the full voltage range, but the semiconductor devices have non-optimal Figure of Merit (FOM) and higher costs
Solution Approach 1:
The battery pack is divided into multiple series-connected battery modules (e.g., 5 modules of 24V each for a 120V system). Each module operates within a narrow voltage range (e.g., 22-28V), allowing the use of optimized semiconductor devices for each module's voltage level rather than requiring devices rated for the full battery voltage range.
Solution Approach 2:
The system dynamically switches between different battery modules as they charge and discharge. The controller monitors module voltages and reconfigures which modules are connected in series to maintain the total output voltage within the target range, adapting to changing battery states without requiring wide-voltage-rated components.
2Power
If the converter is designed to handle high power levels (e.g., 3kW load), then the load power requirement is met, but high currents are experienced that impact efficiency and require larger, more expensive passive and active components
Solution Approach 1:
The high power conversion is divided into multiple parallel converter channels, each handling a portion of the total power. By segmenting the power conversion task, each converter operates at lower current levels, improving efficiency and allowing the use of smaller, less expensive components while collectively delivering the required high power output.
3Power
If the converter is designed for high power levels (e.g., 3kW), then the load power requirement is met, but the required component sizes increase, reducing power density
Solution Approach 1:
The system uses multiple parallel converter channels, each with its own set of passive components (inductors, capacitors). This segmentation allows each converter to use smaller components optimized for lower power levels, while the combined output delivers high total power, thereby maintaining high power density.
Solution Approach 2:
Multiple converter channels are merged in parallel to deliver high total power output. The individual converters, each with modest component sizes, work together to provide the required high power capability, achieving both high power delivery and high power density through the combined system.
Data Source
AI summary
This disclosure includes novel ways of implementing a power supply that powers a load. A main battery source produces a main battery voltage; each of multiple auxiliary battery sources in a set produces a respective auxiliary battery voltage. A controller initially sets a battery supply voltage to the main battery voltage, the main battery voltage is supplied to a power converter. The controller then monitors a magnitude of the battery supply voltage and adjusts the battery supply voltage supplied to the power converter based on a comparison of the magnitude of the battery supply voltage with respect to a threshold level. The adjusted battery supply voltage is provided from a serial connection of the main battery source and a first auxiliary battery source in the set.