Cascaded Battery Module Charging With Per-Module Balancing Control
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Solution Overview
Problem
Existing energy systems for electric vehicles (EVs) lack the ability to monitor individual cell health, state of charge, temperature, and adjust power draw per cell, leading to inefficient performance, reduced battery life, and safety concerns.
Innovation Solution
The development of modular energy systems with multiple modules arranged in cascaded fashion, each equipped with an energy source and switch circuitry, allowing for selective coupling of energy sources to other modules for power generation or storage. These systems can be charged with multiphase AC, single phase AC, or DC signals and include a control system that maintains balanced operating conditions across modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional battery packs with simple BMS are used, then device complexity is reduced, but measurement precision of individual cell health, state of charge, and temperature deteriorates
Solution Approach 1:
The battery pack is divided into multiple independent modules, each with its own BMS capable of monitoring individual cell parameters. This segmentation allows precise measurement of each cell's health, state of charge, and temperature while keeping each module's complexity manageable through modular design
Solution Approach 2:
The system transitions from monitoring individual cells to monitoring modules as the primary unit, adding a hierarchical dimension. Each module aggregates cell data and presents module-level state to the central controller, reducing communication overhead and complexity while maintaining measurement precision through distributed sensing
2Ease of operation
If conventional charging systems with steady constant feed are used, then ease of operation is improved, but productivity of charging process deteriorates
Solution Approach 1:
The charging system dynamically adjusts charging parameters based on real-time module state feedback. The central controller modulates charging current and voltage for each module according to its state of charge, temperature, and health status, enabling faster charging while maintaining safety and balance
Solution Approach 2:
The system implements periodic measurement and adjustment cycles, continuously monitoring module parameters and updating charging strategies. This periodic control enables pulsed charging patterns that improve charge transfer efficiency and allow for thermal management, increasing overall charging productivity
3Measurement precision
If modular energy systems with individual module control are implemented, then measurement precision and control capability are improved, but device complexity increases
Solution Approach 1:
Each module is designed with universal functionality, including identical power conversion circuitry, monitoring capabilities, and control interfaces. This universality allows the system to scale by simply adding or removing modules without increasing per-module complexity, as each module performs multiple functions (power conversion, monitoring, communication) within a standardized platform
Solution Approach 2:
The system merges the functions of power conversion, monitoring, and control into integrated module-level units. Each module combines DC-DC conversion capabilities with embedded BMS functionality, reducing the need for separate components and simplifying the overall system architecture while maintaining precise module-level control
4Reliability
If the weakest cell constrains the entire battery pack, then reliability is improved through conservative operation, but productivity of the battery pack deteriorates
Solution Approach 1:
The system applies local quality control by allowing different modules to operate at different power levels based on their individual cell conditions. Modules with healthier cells can contribute more power, while modules with weaker cells operate conservatively. This local differentiation enables the battery pack to achieve higher overall productivity without compromising reliability, as each module operates within its safe limits
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.