Cascaded Battery Modules for Balanced Charging and Cell Monitoring
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Solution Overview
Problem
Existing energy systems in vehicles and stationary applications lack the ability to monitor individual cell health, adjust power draw per cell, optimize charging flows, and adapt to next-generation motors, leading to reduced battery performance, reliability, and inefficient energy management.
Innovation Solution
A modular energy system with cascaded modules that include energy sources and switch circuitry, capable of receiving and storing power, and outputting status information to a control system for balanced charging and discharging across modules, supporting single or multiphase topologies, and integrating with motors and auxiliary loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional battery packs with simple BMS are used, then manufacturing cost is reduced, but the ability to monitor individual cell health and optimize charging is lost
Solution Approach 1:
The battery pack is divided into multiple modular sub-assemblies, each with its own integrated BMS that monitors individual cell health. This segmentation allows precise cell-level monitoring while distributing system complexity across independent modules rather than requiring a single complex centralized BMS.
Solution Approach 2:
Each modular sub-assembly includes an integrated BMS that autonomously monitors its own cells and manages its charging/discharging operations. This self-service capability eliminates the need for complex external monitoring systems while maintaining precise cell health tracking.
2Productivity
If steady constant charging is applied, then charging system simplicity is maintained, but charging efficiency and battery life are reduced
Solution Approach 1:
The charging system dynamically adjusts charging parameters based on real-time cell status feedback from the BMS. This dynamic control enables pulsed charging and optimized charge rates that improve charging efficiency and battery life, while the modular architecture keeps control complexity manageable through distributed intelligence.
Solution Approach 2:
The system implements pulsed charging sequences with periodic rest intervals, allowing thermal management and cell equalization. This periodic charging pattern improves overall charging efficiency and battery longevity compared to continuous steady charging, while the modular BMS manages the timing and parameters efficiently.
3Productivity
If the weakest cell constrains the entire battery pack, then cell uniformity is maintained, but overall battery performance is reduced
Solution Approach 1:
By segmenting the battery pack into independent modular sub-assemblies, each module can be optimized and balanced independently. This allows the system to maximize overall performance by utilizing stronger cells in other modules without being constrained by the weakest cell in one module, while maintaining pack reliability through modular redundancy.
Solution Approach 2:
Each modular sub-assembly has its own BMS that applies localized control strategies tailored to the specific characteristics of cells in that module. This local quality approach allows optimal performance extraction from each module while maintaining overall system reliability, rather than applying a uniform constraint across the entire pack.
4Ease of repair
If entire battery pack replacement is required upon cell failure, then system simplicity is maintained, but cost and downtime increase
Solution Approach 1:
The battery pack is segmented into independent modular sub-assemblies that can be independently replaced. If a cell or BMS fails in one module, only that specific module needs to be replaced rather than the entire pack, significantly reducing maintenance costs and downtime while maintaining high system reliability through modular redundancy.
Solution Approach 2:
The modular architecture enables selective replacement of only the failed module while recovering and continuing to use the remaining healthy modules. This approach dramatically improves ease of repair and reduces waste compared to replacing the entire battery pack, while maintaining reliable operation through the remaining functional modules.
5Loss of energy
If regenerative braking power is dissipated via dump resistor, then battery protection is ensured, but energy efficiency is reduced
Solution Approach 1:
The system dynamically manages regenerative braking energy based on real-time battery state feedback. When battery conditions permit, the modular BMS directs regenerative power to available modules for storage. When modules are full or conditions are unfavorable, the system safely dissipates excess energy through the dump resistor, optimizing energy recovery while ensuring battery protection.
Solution Approach 2:
The system recovers regenerative braking energy by directing it to available battery modules for storage, maximizing energy efficiency. When modules are at capacity or battery conditions prevent charging, the system safely discards excess energy through the dump resistor, protecting the battery while minimizing energy loss through intelligent routing decisions.
Data Source
AI summary
Example embodiments of systems, devices, and methods are provided for charging and discharging energy systems having multiple modules arranged in cascaded fashion for generating and storing power. Each module can include an energy source and switch circuitry that selectively couples the energy source to other modules in the system for generating power or for receiving and storing power from a charge source. The energy systems can be arranged in single phase or multiphase topologies with multiple serial or interconnected arrays. The embodiments are capable of being charged with multiphase AC charge signals, a single phase AC charge signal, and/or a DC charge signal. Embodiments implementing the modular energy system within a charge source for performing multiphase, single phase AC, or DC charging of electric vehicles are also disclosed. Also disclosed are multi-motor embodiments and embodiments with the capability to power active suspensions and active steering systems.