Cascadable Multi-Charger Segmentation for Connector Volume Reduction
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Solution Overview
Problem
Existing multi-chargers for battery packs face limitations in efficiently charging high-energy battery packs within short times, requiring large and costly connectors due to high current loads, and lack modular scalability for safe and reliable operation.
Innovation Solution
A modular charging device system where each charging device has an input-side and output-side contact element for cascading connections, with internal conductors for power supply voltage looping, a voltage converter for local power generation, and signal transmission for position information to limit the number of connected devices, allowing for automatic deactivation to prevent overloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a central network part supplies power to multiple charging trays in parallel, then the charging capacity is sufficient for high-energy battery packs, but the conductor cross sections and plug-in connectors must be dimensioned for high current loads, leading to large volume and high costs
Solution Approach 1:
The charging system is segmented into multiple independent charging devices, each with its own network part and voltage converter. Instead of one central network part supplying multiple trays in parallel (requiring high-current connectors), each charging device operates independently with low-current connectors. This segmentation distributes the power conversion function across multiple units, eliminating the need for high-current bus bars and large-volume connectors while maintaining total charging capacity.
2Productivity
If multiple charging trays are connected in parallel to a central network part, then multiple battery packs can be charged simultaneously, but the device complexity and configuration difficulty increase
Solution Approach 1:
The system is divided into independent, identical charging device modules that can be connected in series. Each module is a self-contained unit with complete functionality (network part, voltage converter, charging controller). This modular segmentation allows simple daisy-chain connection without complex parallel wiring, reducing configuration difficulty while maintaining simultaneous charging capability across multiple modules.
Solution Approach 2:
Instead of connecting multiple charging trays in parallel (same dimension), the invention connects charging devices in series along a chain (different dimension). This topological change from parallel to series arrangement simplifies the connection scheme, as each device connects to only two neighbors (input and output contacts), eliminating the complexity of distributing power to multiple parallel connections.
3Quantity of substance
If charging devices are connected in a chain with power supply voltage looped through, then the current load on conductors is reduced, but position information must be transmitted and analyzed to limit the number of connected devices
Solution Approach 1:
Each charging device includes a signal transmitter that sends position information (number of predecessors in the chain) to subsequent devices, and a signal receiver that receives position information from predecessor devices. This feedback mechanism allows each device to automatically determine its position in the chain and compare it against a predefined limit value, enabling automatic deactivation when the maximum number of devices is reached, without requiring complex centralized control.
Solution Approach 2:
Each charging device autonomously determines its own position in the chain by receiving position information from its predecessor and transmitting its position to its successor. The device independently compares its position against the limit value and decides whether to remain active or deactivate, without requiring external control or complex system-wide coordination. This self-service approach simplifies the overall control system while managing the chain configuration.
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
This solution reduces the need for large connectors, simplifies configuration, and ensures safe, efficient charging of multiple battery packs by limiting the number of connected devices, thereby reducing costs and ensuring reliable operation without the need for a central network part.
Implementation Method 1
The power supply voltage UV can be converted within the charging device by means of the voltage converter into a supply voltage for feeding the charging controller
Data Source
AI summary
A charging device, for charging a battery pack, can be combined with other charging devices to form a multi-charger. The charging device has an input-side contact element for a power cable or an additional charging device connection. Internally, the charging device has conductors for the electrically conductive connection of the input-side contact element to an output-side contact element and for looping through a power supply voltage in contact with the input-side contact element. A charging device circuit of the charging device is internally connected to the looped-through supply voltage. The charging device circuit includes an input side voltage converter and a charging controller for charging a battery pack. The supply voltage can be converted by the voltage converter into a supply voltage for feeding the charging controller.