Battery Test Power Control Using a Built-In Battery Buffer
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Solution Overview
Problem
Existing battery charge/discharge testing devices face inefficiencies in power consumption due to wasted power from discharge power regeneration, particularly in high-current specifications, where discharge power cannot be fully utilized and results in unnecessary consumption by control power supplies and cooling fans.
Innovation Solution
A battery charge/discharge testing device and method that incorporates a main DC/DC conversion unit and a sub-DC/DC conversion unit, utilizing duty-ratio control to efficiently store discharge power in a built-in battery during discharge tests and use it as a power supply during charge tests, optimizing power utilization through duty-ratio controlled ON/OFF operations of switching elements in full-bridge circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If self-regeneration method is used to deal with power regeneration during discharging operation, then discharge power can be consumed in the circuit on the DC power supply side, but discharge power that cannot be consumed is forced to be consumed in a discharge circuit resulting in wasted power consumption
Solution Approach 1:
An energy storage device (capacitor or rechargeable battery) is introduced as an intermediary component between the DC power supply circuit and the discharge circuit. This intermediary stores excess discharge power that cannot be immediately consumed by the control power supply or cooling fan, preventing energy waste while maintaining circuit simplicity. The energy storage device acts as a buffer that decouples the power generation and consumption processes.
2Power
If high-current specifications are implemented in battery charge/discharge testing devices, then testing capability is improved, but power consumption increases and efficiency decreases
Solution Approach 1:
The system maintains continuous useful action by recycling discharge power back into the system through the energy storage device. During discharging operation, excess power is stored rather than wasted, and during charging operation, this stored power is reused to supplement the DC power supply. This continuous recycling of energy maintains high testing current capability while improving overall power consumption efficiency.
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 solution enables efficient use of discharge power generated during battery discharging, reducing unnecessary power consumption by storing and reusing it for charging, thereby enhancing the overall efficiency of the testing process.
Implementation Method 1
The bidirectional DC-DC converter is composed of a full-bridge circuit in which four switching elements are bridge-connected
Implementation Method 2
a battery is connected to the other terminal through a choke coil
Data Source
AI summary
The battery charge/discharge testing device includes a sub-charge/discharge unit connected to a main charge/discharge unit through bus lines, wherein when an output voltage of a built-in battery in the sub-charge/discharge unit is in a voltage range capable of supplying power, sub-power supply control is executed to supply discharge power of a built-in battery between the bus lines through a full-bridge circuit in a sub-DC/DC conversion unit by duty-ratio controlling ON/OFF of switching elements of the full-bridge circuit so that the voltage between the bus lines becomes a first predetermined voltage value. When the voltage exceeds the first predetermined voltage value during the sub-power supply control, the control is stopped, and constant current charge control is executed to charge the built-in battery through the full-bridge circuit by using, as a power supply, discharge power of the test battery supplied between the bus lines by duty-ratio controlling ON/OFF of the switching elements.