Hybrid Battery Test Channels for Series Formation Precision
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Solution Overview
Problem
Existing battery testing systems face challenges in achieving precise and cost-effective formation and testing of batteries in both parallel and series configurations, particularly in balancing current distribution and voltage equalization across batteries with varying states of charge and health.
Innovation Solution
A hybrid serial battery testing system comprising a high voltage high current (HVHC) and low voltage low current (LVLC) channels, where HVHC channels provide simultaneous testing of batteries in series and LVLC channels offer precise, independent testing in parallel, with current distribution balanced across batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single high voltage high current (HVHC) battery testing system is used to test multiple batteries in series, then productivity is improved by simultaneous testing, but measurement precision deteriorates due to inability to provide precise low current measurements
Solution Approach 1:
The patent combines an HVHC BTS and an LVLC BTS into a hybrid testing system where both systems work together on the same battery string. The HVHC BTS provides high current for formation and bulk charging, while the LVLC BTS provides precise low current measurements and equalization, merging the capabilities of both systems to overcome their individual limitations.
Solution Approach 2:
The hybrid system serves multiple functions simultaneously: the HVHC channel performs high-current formation and bulk charging, while the LVLC channel performs precise measurements, equalization, and low-current testing. This multi-functionality allows a single testing setup to handle diverse battery testing requirements without needing separate dedicated systems.
2Productivity
If high current is used for battery formation, then productivity is improved by faster charging, but energy consumption increases and voltage control precision deteriorates
Solution Approach 1:
The system uses periodic switching between high-current formation mode and low-current equalization mode. During bulk charging, high current is applied for rapid energy transfer, then the system switches to low-current mode for precise equalization and measurement, creating a periodic cycle that optimizes both speed and precision throughout the formation process.
Solution Approach 2:
The system dynamically changes current parameters during the formation process. It starts with high current for rapid charging, then progressively reduces current as batteries approach full charge, and switches to low current for equalization. This parameter adaptation allows the system to optimize energy efficiency at different stages of battery formation.
3Measurement precision
If separate testing systems are used for high current and low current measurements, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
Instead of using completely separate testing systems, the patent merges the HVHC and LVLC BTS into a single hybrid system that shares common infrastructure such as battery connections, control interfaces, and data acquisition systems. This reduces overall system complexity while maintaining the measurement precision benefits of having both high-current and low-current capabilities.
4Manufacturing precision
If voltage equalization is performed across all batteries simultaneously, then manufacturing precision is improved by ensuring uniform charge, but device complexity increases due to additional control requirements
Solution Approach 1:
The system applies local quality control by using the LVLC channel to provide individualized low-current equalization to each battery or small groups of batteries based on their specific voltage states. Rather than applying uniform control to all batteries, the system tailors the equalization current to each battery's needs, improving precision while using simple control logic.
Data Source
AI summary
A high voltage high current (HVHC) battery testing system (BTS) is provided that has a plurality of HVHC channels for testing multiple batteries simultaneously, where each HVHC channel provides programmed current, voltage or power, and where each HVHC channel is configured to test multiple batteries connected in a series configuration simultaneously. A low voltage low current (LVLC) BTS has a plurality of LVLC channels, where an LVLC channel is connected to each of the batteries or to each group of the batteries in a parallel configuration. Each LVLC channel provides programmed current, voltage or power according to a preloaded schedule or to a command from a control unit. The LVLCBTS is configured to provide measurement, storage and transfer of test data according to a programmed schedule. The HVHCBTS and the LVLCBTS are configured to pass current through each battery simultaneously, where the current passed through each battery by the LVLCBTS is less than 10% of the current passed through each battery by the HVHCBTS.