Flexible Energy-Storing Cable with Supercapacitor Balancing Control
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Solution Overview
Problem
Existing energy storage systems face challenges in efficiently integrating supercapacitors and power management circuitry into a flexible cable form factor, leading to space constraints, design tradeoffs, and complexity in managing large numbers of supercapacitors.
Innovation Solution
A flexible energy storing cable with individual energy storage modules, each comprising capacitors and switching devices connected to a microcontroller for voltage balancing and power management, allowing for a flexible and compact hybrid energy storage system that isolates supercapacitors from the load and source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple individual supercapacitor modules are integrated into a flexible cable, then the energy storage capacity and flexibility are improved, but the device complexity and difficulty of managing individual modules increase
Solution Approach 1:
The cable is divided into multiple discrete energy storage modules, each containing one or more supercapacitors with individual switching devices. This segmentation allows independent management and balancing of each module while maintaining overall system flexibility and energy storage capacity.
Solution Approach 2:
A microcontroller serves as an intermediary to manage the multiple individual modules. It monitors voltage levels across all modules and controls switching devices to balance charges, simplifying the management complexity by providing centralized control over the segmented modules.
2Productivity
If individual switching devices are connected to each supercapacitor module for voltage balancing, then the energy storage efficiency is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
Multiple switching devices and balancing circuitry are merged into integrated modules that can be manufactured as standardized units. Each module contains the supercapacitor, switching device, and associated circuitry, simplifying the manufacturing process while maintaining individual voltage balancing capability.
Solution Approach 2:
The switching devices are designed with universal functionality to handle multiple tasks: voltage balancing, power management, and protection. This multi-functionality reduces the need for separate components and simplifies the overall manufacturing process.
3Reliability
If a rigid circuit board is used to mount supercapacitors, then the electrical connection reliability is improved, but the flexibility and adaptability of the energy storage system are reduced
Solution Approach 1:
The rigid circuit board structure is replaced with a flexible cable assembly that maintains reliable electrical connections through flexible printed circuits or welded connections. This allows the energy storage system to be bent and adapted to different spatial configurations while maintaining connection reliability.
Solution Approach 2:
The system transitions from a static rigid circuit board to a dynamic flexible cable structure that can adapt its shape and positioning. The flexible design allows the energy storage system to be installed in various configurations without compromising electrical connection reliability.
4Ease of manufacture
If passive balancing with voltage divider circuits is used, then the manufacturing cost is reduced, but the balancing speed and energy efficiency are reduced
Solution Approach 1:
The passive mechanical/resistive balancing system is replaced with an active electronic control system using switching devices and microcontrollers. This substitution enables faster and more efficient charge redistribution while maintaining reasonable manufacturing costs through integrated circuit design.
5Productivity
If active balancing with DC/DC converters is used, then the balancing efficiency is improved, but the manufacturing cost and device complexity increase
Solution Approach 1:
The complex DC/DC converter functionality is extracted and implemented as integrated switching circuits controlled by a microcontroller, rather than using full-blown DC/DC converter modules. This maintains high balancing efficiency while reducing device complexity and manufacturing cost.
Solution Approach 2:
The system uses the supercapacitors themselves to perform the balancing function by transferring charge directly between modules through switching devices, eliminating the need for external DC/DC converters. This self-service approach maintains efficiency while reducing complexity.
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
The solution enables efficient use of supercapacitor capacity, reduces design complexities, and provides a compact, flexible energy storage solution suitable for various applications, including those with space constraints, by integrating power management directly into the cable.
Implementation Method 1
a plurality of individual energy storage modules contained within the sheath, each module comprising at least one capacitor
Data Source
AI summary
A flexible energy storing cable contains a plurality of individual supercapacitors and their respective balancing circuits, along with a single control circuit to manage all of the individual balancing circuits through a data link, which may be wired within the cable or may be wireless. The cable is preferably flexible enough to bend around a radius of about five times its diameter or less. The system may contain further modules such an AC/DC converter, DC/DC converter, DC/AC converter, source control, etc., which may be external to the cable or integrated within the cable if size permits. A supercapacitor management system and/or a hybrid energy storage isolation system may be integrated in-line into the energy storing cable.