CHIL Testbed for Second-Life Battery Assessment
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Solution Overview
Problem
Lithium-ion batteries in electric vehicles and microgrids face electrical instabilities due to chemical variations, leading to voltage imbalances and premature degradation, and existing battery management systems often incorrectly identify second-life battery readiness, resulting in early removal.
Innovation Solution
A control-hardware-in-the-loop testbed with a simulation bench, including a battery cell simulator, temperature simulator, and programmable power supply, is used to simulate and analyze battery performance, allowing for constrained cycling and improved voltage balancing, thereby extending the life of second-life batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If batteries undergo extensive cycling to assess second-life readiness, then more accurate performance assessment is achieved, but battery degradation accelerates and useful life is reduced
Solution Approach 1:
The patent creates virtual copies of batteries through digital twins that replicate physical battery behavior, chemistry, and degradation patterns. These digital models allow comprehensive performance assessment through simulated cycling without subjecting physical batteries to degrading test cycles. The digital twin can undergo extensive virtual cycling to assess second-life readiness while the physical battery remains intact and functional.
Solution Approach 2:
The system performs preliminary assessment actions by creating and analyzing digital twins before subjecting physical batteries to extensive cycling tests. By using machine learning models trained on historical data, the system can predict battery performance and second-life potential early in the process, reducing the need for lengthy physical cycling tests that would accelerate degradation.
2Reliability
If strict monitoring and protection are implemented for second-life batteries, then safety and performance are improved, but system complexity increases
Solution Approach 1:
The patent introduces digital twins as intermediary layers between physical batteries and monitoring systems. These virtual models simplify complex monitoring by providing standardized interfaces that translate diverse battery parameters into unified performance metrics. The digital twin acts as a mediator that processes sensor data and provides actionable insights without requiring complex direct monitoring of every physical parameter.
Solution Approach 2:
The monitoring system achieves multiple functions through the digital twin platform: performance prediction, safety monitoring, degradation tracking, and second-life assessment all occur within a single unified system. This multi-functional approach reduces overall system complexity compared to implementing separate specialized systems for each monitoring function.
3Measurement precision
If existing BMS incorrectly identify second-life battery readiness, then early removal occurs and resource waste increases, but improving identification accuracy requires more sophisticated testing
Solution Approach 1:
The patent uses digital twins to create accurate virtual representations of battery state and performance characteristics. These digital copies enable precise identification of second-life readiness by comparing actual battery behavior against simulated degradation patterns, significantly improving identification accuracy without requiring physically complex testing apparatus.
Solution Approach 2:
The system improves readiness identification by monitoring and analyzing changes in multiple battery parameters over time through the digital twin model. Machine learning algorithms detect subtle parameter changes and patterns that indicate second-life potential, enabling accurate identification without sophisticated physical testing equipment.
Data Source
AI summary
Testbeds for battery management systems (BMSs) and/or batteries, as well as methods of using the same, are provided. A testbed can be a control-hardware-in-the-loop (CHIL) testbed and can include a simulation bench including a battery cell simulator, a temperature simulator, and/or a real-time simulator. The simulator bench can further include a programmable power supply, a relay, a resistor, and/or a communication protocol.