Dual Charger Heating Mode for Cold Battery Charging
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Solution Overview
Problem
Battery charging systems in cold climates face inefficiencies and increased complexity due to the need for additional heating elements to maintain optimal temperature, especially in applications like vehicular and grid storage batteries, where existing solutions rely on extra heaters and inefficient charger operation.
Innovation Solution
A dual-charger module system where one charger module operates to charge the battery and another module generates heat without delivering charging current, using a stacked half-bridge converter topology and control circuitry to regulate heat production through switching states and frequencies, allowing for efficient heat generation without additional heating elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If additional heating elements are added to the battery system, then heating capability is improved, but device complexity increases
Solution Approach 1:
The charger module is designed to perform multiple functions: normal battery charging and heating mode. By utilizing the existing charger module for both charging and heating purposes, the system eliminates the need for separate heating elements, thereby reducing device complexity while maintaining heating capability
Solution Approach 2:
The heating function is merged with the charger module by configuring it with bidirectional power flow capability. The charger module combines the functions of power conversion and heating generation into a single integrated unit, reducing the overall system complexity
2Temperature
If separate heating elements are used, then heating function is improved, but cost increases
Solution Approach 1:
The charger module serves dual purposes as both a charging device and a heating element. This multi-functionality eliminates the need to manufacture and install separate heating components, thereby reducing manufacturing costs while maintaining effective heating capability
Solution Approach 2:
The heating function is combined with the existing charger module, eliminating the need for separate heating components. This integration reduces the total bill of materials and assembly costs associated with manufacturing the battery system
3Reliability
If charger operates inefficiently in cold conditions, then battery operation is improved, but energy loss increases
Solution Approach 1:
The system performs preliminary heating of the battery before charging begins. By pre-heating the battery to optimal temperature conditions, the subsequent charging process operates more efficiently, reducing energy losses during the main charging operation
Solution Approach 2:
The system converts what would normally be wasted energy (charger losses) into useful heating during cold conditions. By operating the charger in heating mode when ambient temperatures are low, the energy that would otherwise be lost is converted into beneficial thermal energy for battery temperature regulation
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 solution enables efficient heat generation within the charger itself, reducing complexity and cost by eliminating the need for separate heaters and improving battery system operation in cold conditions while maintaining optimal temperature ranges.
Implementation Method 1
the second control circuitry operates the second charger to generate heat without delivering charging current to the battery
Data Source
AI summary
A battery charging system can include a first charger module having a first AC side couplable to an AC source and a first DC side couplable to a battery and first control circuitry that operates the first charger to charge or discharge the battery; and a second charger module having a second AC side couplable to the AC source and a second DC side couplable to the battery and second control circuitry that operates the second charger to generate heat, wherein: if the first charger module is charging the battery from the AC source, the second control circuitry operates the second charger to generate heat without delivering charging current to the battery; and if the second charger is discharging the battery to the AC source, the second control circuitry operates the second charger to generate heat without delivering current to the AC source.