Hierarchical DC-DC Converter Topology for Energy Storage Testing
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Solution Overview
Problem
Current cell testers are inefficient, costly, and inflexible due to the use of linear position controllers and complex regenerative switching converters, leading to high energy losses and cooling costs during battery testing and formation.
Innovation Solution
A hierarchical test arrangement with multiple module DC-DC converters connected in parallel to an AC-DC converter, allowing for flexible configuration and efficient energy distribution by using switches to connect outputs in series, prioritizing the highest converter stage for energy supply and enabling efficient testing and emulation of energy storage units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If linear position controllers are used in cell testers, then the device complexity is reduced, but the efficiency deteriorates and energy losses increase
Solution Approach 1:
The patent changes the control parameter from linear position control to pulse-width modulation (PWM) switching control, enabling efficient energy transfer while maintaining manageable device complexity through standardized converter modules
2Loss of energy
If regenerative switching converters are used to map high voltage ratio (3V to 400V), then the efficiency is improved, but the device complexity and cost increase
Solution Approach 1:
The patent segments the voltage conversion function into multiple hierarchical DC-DC converter stages (module level and cell level), each handling a portion of the voltage ratio, thereby reducing the complexity of individual converters while maintaining high efficiency
Solution Approach 2:
The patent implements a nested converter architecture where cell DC-DC converters are nested within module DC-DC converters, which are in turn nested within the overall test arrangement, allowing efficient energy transfer through hierarchical power management
3Adaptability or versatility
If the test arrangement structure is changed to test different energy storage configurations, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The patent creates a universal test arrangement architecture where the same hierarchical DC-DC converter structure can test various energy storage configurations (individual cells, modules, or complete packs) by simply reconfiguring connections rather than changing the fundamental device structure
Solution Approach 2:
The patent introduces dynamic reconfigurability through controllable switches that allow the test arrangement to adapt its topology in real-time, enabling transition between different testing modes without physical reconfiguration of the converter structure
4Device complexity
If linear position controllers are used, then the cooling system requirements are reduced, but the efficiency deteriorates and energy costs increase
Solution Approach 1:
The patent changes the operating parameters of the power conversion system by using PWM switching control instead of linear control, achieving high efficiency operation that minimizes heat generation and reduces cooling system requirements
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 hierarchical structure achieves an efficiency advantage of approximately 17% by utilizing the highest converter stage for most of the test time, reducing energy losses and increasing flexibility in testing and forming energy storage devices, from individual units to entire modules.
Implementation Method 1
an AC/DC converter which is connected to a voltage supply on the input side and is connected to at least one bidirectional, isolated module DC/DC converter on the output side
Data Source
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AI summary
The invention relates to an efficient, economical, and at the same time flexibly usable or configurable testing assembly for energy stores comprising several energy storage modules for several energy storage units each. According to the invention an AC/DC converter (2) is connected on the output side to at least one bidirectional isolated module DC/DC converter (51...5n), wherein the output of the bidirectional isolated module DC/DC converter (51...5n) is connected to a plurality of cell DC/DC converters (611...6nm) connected in parallel and the outputs of the cell DC/DC converters (611...6nm) are fed outside as outputs (A1+, A1-...Ax+, Ax-) of the testing assembly (1).