Dual-Active-Bridge Converter for Galvanic Isolation in Energy Storage

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Solution Overview

Problem

Existing energy storage systems face scalability limitations when paralleling batteries, requiring precise voltage matching and specific cell types, which restricts system flexibility and makes them vulnerable to failure due to the weakest link.

Innovation Solution

The implementation of a power electronics interface with galvanic isolation allows for the use of different cell types, ages, and voltages, enabling independent operation of cells within a DC microgrid, eliminating failure propagation and enhancing scalability by using a dual-active-bridge converter and DC/DC converters for efficient power management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If batteries are paralleled to increase capacity, then the energy storage capacity increases, but the system requires precise voltage matching and complex management strategies

Engineering Contradiction:
Improveenergy storage capacityVSAvoidmanagement strategy complexity
Core Design Contradiction:
Quantity of substanceVSDevice complexity

Solution Approach 1:

The system segments the battery array into multiple independent modules, each with its own DC/DC converter. This segmentation allows each module to operate independently with its own voltage characteristics, eliminating the need for precise voltage matching between parallel batteries while reducing overall system complexity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

DC/DC converters are introduced as intermediary devices between individual battery modules and the common DC bus. These converters act as mediators that isolate voltage differences between modules, allowing batteries with different voltages, chemistries, and ages to be connected without requiring complex balancing strategies.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Quantity of substance

If batteries are paralleled electrically, then the energy storage capacity increases, but the system is limited by the weakest link and vulnerable to failure propagation

Engineering Contradiction:
Improveenergy storage capacityVSAvoidsystem vulnerability to failure
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The system divides the battery array into electrically isolated modules, each controlled by its own DC/DC converter. This segmentation ensures that a failure in one module does not propagate to other modules, as each module operates independently with its own protection and control circuitry.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The system incorporates individual DC/DC converters for each battery module that provide electrical isolation and protection before failures can propagate. These converters act as protective barriers that prevent fault propagation, allowing the system to tolerate individual cell or module failures without taking the entire system offline.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If precise voltage matching is required for parallel batteries, then the system can operate reliably, but the scalability is significantly limited

Engineering Contradiction:
Improveoperational reliabilityVSAvoidsystem scalability
Core Design Contradiction:
ReliabilityVSAdaptability or versatility

Solution Approach 1:

DC/DC converters serve as intermediary devices that decouple the voltage matching requirement from the parallel battery configuration. Each converter independently regulates its module's voltage, allowing batteries with different voltage characteristics to be connected to the common DC bus without compromising reliability.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The system allows for parameter changes in battery modules (voltage, capacity, chemistry, age) by using DC/DC converters that can adapt to different module characteristics. Each converter is configured to match its specific module's parameters, enabling scalable system expansion with diverse battery types without requiring uniform voltage matching across all modules.

Inventive Principle:
Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables the creation of scalable energy storage systems that can handle diverse cell types and ages, ensuring system reliability and efficiency by isolating cells and allowing for independent failure, thus preventing a single cell failure from taking down the entire system.

Implementation Method 1

dual-active-bridge converter

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10277029B2Energy storage system with dual-active-bridge converter
Publication Date: 2019.04.30 TESLA INC
  • US10277029B2 patent drawing
  • US10277029B2 patent drawing
  • US10277029B2 patent drawing

AI summary

An energy storage device includes: a number of cells; and a dual-active-bridge converter connected to the cells, wherein the cells are floating relative to the system and are galvanically isolated therefrom. The energy storage device can be included in an energy storage system that includes: a grid tie unit comprising at least one DC/AC converter; and multiple pods connected to the grid tie unit, each pod including: a number of cells; and a power electronics unit, wherein the cells are floating relative to the system and are galvanically isolated therefrom.