Independent DC/DC Converter Load Sharing for Battery SoC Balance

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Solution Overview

Problem

The uneven wear on batteries in electric and hybrid-electric propulsion systems for aircraft poses challenges in maintaining efficient power distribution and balancing the State of Charge (SoC) of batteries, leading to potential system capacity limitations and voltage instability.

Innovation Solution

A power balancing control scheme is implemented using multiple independent DC/DC converters that regulate voltage on a common power bus, allowing for dynamic adjustment of power share among batteries to balance SoC, avoid overloading, and maximize system capacity without requiring a master/slave architecture or high-speed communication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple independent DC/DC converters are used to regulate voltage on a common power bus, then voltage stability is improved and system capacity is maximized, but power distribution control complexity increases

Engineering Contradiction:
Improvevoltage stabilityVSAvoidpower distribution control
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The power distribution system is segmented into multiple independent DC/DC converters, each with its own controller that independently regulates voltage on the common power bus. This segmentation allows parallel operation of converters, improving reliability and system capacity while distributing control complexity across multiple simple units rather than one complex centralized controller.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Each DC/DC converter controller autonomously monitors the common power bus voltage and adjusts its own output to maintain voltage stability. The converters self-regulate based on local measurements and simple control logic, eliminating the need for complex centralized coordination and high-speed communication infrastructure.

Inventive Principle:
Principle #25Self-service

2Duration of action of stationary object

If power share among batteries is dynamically adjusted to balance State of Charge, then battery wear is equalized and system capacity is extended, but control complexity increases

Engineering Contradiction:
Improvebattery system capacityVSAvoidpower balancing control
Core Design Contradiction:
Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The control system continuously monitors the State of Charge of each battery and uses this feedback to dynamically adjust the power share allocated to each DC/DC converter. This feedback mechanism equalizes battery wear by directing charging/discharging loads away from batteries with extreme SoC levels, extending overall system capacity without requiring complex control algorithms.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The power share allocation is made dynamic rather than fixed, allowing the system to adapt in real-time to changing battery conditions. The control scheme automatically redistributes power demands among batteries based on their current State of Charge, enabling flexible load management that extends system capacity while keeping control logic relatively simple.

Inventive Principle:
Principle #15Dynamics

3Reliability

If master/slave architecture is avoided in favor of independent converters, then system reliability is improved and single-point failures are eliminated, but coordination complexity increases

Engineering Contradiction:
Improvesystem reliabilityVSAvoidconverter coordination
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The system is divided into multiple independent DC/DC converter units, each with its own controller that operates autonomously. This segmentation eliminates the master/slave hierarchy and single points of failure, as each converter can independently regulate voltage and continue operating even if others fail. The coordination complexity is reduced by making each unit simple and self-sufficient.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Each DC/DC converter controller independently monitors the common power bus voltage and self-adjusts its output contribution without requiring complex coordination with other converters. This self-service approach improves reliability by eliminating dependency on centralized control while keeping individual converter control logic simple and robust.

Inventive Principle:
Principle #25Self-service

4Device complexity

If high-speed communication is eliminated between converters, then system complexity and cost are reduced, but real-time coordination capability is limited

Engineering Contradiction:
Improvecommunication infrastructureVSAvoidresponse to load changes
Core Design Contradiction:
Device complexityVSSpeed

Solution Approach 1:

Each DC/DC converter controller independently monitors the common power bus voltage in real-time and immediately adjusts its output in response to voltage deviations or load changes. This self-service control eliminates the need for high-speed communication between converters, reducing system complexity and cost while maintaining fast response times through local autonomous decision-making.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The control system uses local feedback from voltage sensors on the common power bus to drive immediate corrective action by individual converters. This feedback mechanism enables real-time response to load changes without requiring communication overhead, as each converter reacts autonomously to voltage conditions it directly measures.

Inventive Principle:
Principle #23Feedback

Data Source

PatentUS11901758B2Loading sharing across multiple power supplies
Publication Date: 2024.02.13 GENERAL ELECTRIC CO
  • US11901758B2 patent drawing
  • US11901758B2 patent drawing
  • US11901758B2 patent drawing

AI summary

A power system (150) operable to implement a power balancing control scheme is provided. In one aspect, a power system (150) includes multiple independent power supplies (182A, 182B) with independent batteries (172A, 172B) feeding onto a common power bus (180). The power supplies (182A, 182B) regulate the voltage on the common power bus (180) at the same time. The power balancing control scheme, when implemented, causes the load on the common power bus (180) to be shared among the individual power supplies (182A, 182B) with a specified load distribution. The specified load distribution can be set or determined to balance the State of Charge (SoC) of the batteries (172A, 172B) over time whilst taking into account the constraints or limits of the elements (172A, 172B, 182A, 182B) of the power system (150).