Battery Charger Wake-Up Voltage Control for Inrush Current
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Solution Overview
Problem
Inrush current is generated when there is a significant voltage difference between a charger and a battery, leading to inefficiencies and potential damage.
Innovation Solution
A charging system with a controller that detects battery voltage, determines a charging start voltage based on the battery voltage, and outputs a wake-up voltage to activate the battery management module, followed by a controlled charging current and voltage to manage the inrush current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If charging voltage is applied immediately upon connection detection, then charging speed is improved, but inrush current increases causing potential damage and inefficiency
Solution Approach 1:
The charger outputs a wake-up voltage before the main charging voltage to activate the battery management module in advance. This preliminary action allows the system to prepare for charging by establishing communication and determining appropriate charging parameters, thereby avoiding sudden inrush current when full charging voltage is applied.
Solution Approach 2:
The system changes the voltage parameter dynamically during the charging initiation process. It starts with a low wake-up voltage to activate the battery management module, then transitions to a predetermined charging voltage based on battery state. This parameter change approach allows controlled charging startup that minimizes inrush current while maintaining charging efficiency.
2Measurement precision
If battery management module is always active, then charging control precision is improved, but energy consumption increases
Solution Approach 1:
The wake-up voltage serves as a preliminary activation signal that temporarily powers the battery management module only when needed - specifically when a charging connection is detected. This allows the module to perform precise voltage detection and communication functions during charging initiation, then enter sleep mode to conserve energy when not in use.
Solution Approach 2:
The battery management module activates itself in response to the wake-up voltage signal without requiring continuous external power. It performs its detection and communication functions autonomously during the charging startup phase, then returns to a low-power state, achieving a balance between functional precision and energy conservation.
3Loss of time
If charging starts without voltage verification, then charging response time is improved, but system reliability decreases
Solution Approach 1:
The system performs preliminary voltage detection and comparison actions before initiating charging. The battery management module measures the battery voltage and compares it with the wake-up voltage threshold to determine whether charging should start. This preliminary verification ensures system reliability by preventing charging under inappropriate conditions, while the automated nature of the check minimizes time loss.
Solution Approach 2:
The system implements feedback control by continuously monitoring battery voltage and comparing it against predetermined thresholds. The battery management module uses this feedback to make intelligent decisions about charging initiation, ensuring that charging only starts when voltage conditions are appropriate. This feedback mechanism maintains high system reliability without significantly delaying charging response.
Data Source
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AI summary
A charging system (100) includes a battery pack (10) including at least one battery cell (12) and a battery management module (11), and a charger (20) including a connector (21) configured to detect a connection with the battery pack (10), a communicator (22) configured to communicate with the battery management module (11), and a controller (23) configured to control charging of the battery pack (10). The controller (23) of the charger (20) is configured to output a wake-up voltage when the connection with the battery pack (10) is detected through the connector (21), receive a value of a battery voltage from the battery management module (11) through the communicator (22), determine a charging start voltage based on the value of the battery voltage, and start charging the battery pack (10) after outputting the charging start voltage.