Hybrid Battery-Supercapacitor Power Control for Pulsed Vehicle Loads

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Solution Overview

Problem

Existing power management systems in transport vehicles face degradation due to pulsed power loads, regenerative braking, and temperature variations, leading to reduced battery capacity and lifetime, which is exacerbated by the need for larger batteries that increase cost, size, and weight, and do not address the challenge of supporting mobile bidirectional power transfer for drones.

Innovation Solution

A hybrid power management system incorporating a battery, super capacitor bank, bidirectional DC/DC converter, and hybrid controller that regulates pulsed power, minimizes battery stress, and enables wireless power transfer, allowing for efficient charging and discharging, extended battery life, and supporting drone recharging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If battery size is increased to handle pulsed power loads and extend operational range, then power capacity and endurance are improved, but cost, size, and weight increase prohibitively

Engineering Contradiction:

Improvepower capacityVSAvoidbattery weight

Core Design Contradiction:

Use of energy by moving objectVSWeight of moving object

Solution Approach 1:

The power storage system is segmented into two distinct components: a battery for energy storage and a supercapacitor bank for power delivery. Each component is optimized for its specific function, allowing the battery to be smaller while still meeting overall power requirements through the combined system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The supercapacitor bank provides excessive power delivery capability during pulsed loads, exceeding what the battery alone could provide. This partial action by the supercapacitor during critical moments allows the battery to be sized for average rather than peak demands.

Inventive Principle:

Principle #16Partial or excessive action

2Use of energy by moving object

If battery size is increased to handle pulsed power loads and extend operational range, then power capacity and endurance are improved, but cost, size, and weight increase prohibitively

Engineering Contradiction:

Improvepower capacityVSAvoidbattery quantity

Core Design Contradiction:

Use of energy by moving objectVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #16Partial or excessive action

3Device complexity

If battery is used to deliver pulsed power directly, then system simplicity is maintained, but battery degradation increases due to power pulses from compressor cycling and regenerative braking

Engineering Contradiction:

Improvesystem complexityVSAvoidbattery lifetime

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The supercapacitor bank acts as an intermediary between the battery and the pulsed power demands. It absorbs power pulses from the compressor and regenerative braking, preventing these stressors from directly affecting the battery and thereby extending battery lifetime.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The hybrid controller autonomously manages power distribution between the battery and supercapacitor bank based on real-time system conditions. It automatically directs pulsed loads to the supercapacitor and manages regenerative braking energy capture, eliminating the need for complex external control systems.

Inventive Principle:

Principle #25Self-service

4Reliability

If battery is used to deliver pulsed power directly, then system simplicity is maintained, but battery degradation increases due to power pulses from compressor cycling and regenerative braking

Engineering Contradiction:

Improvebattery lifetimeVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Inventive Principle:

Principle #25Self-service

5Adaptability or versatility

If battery directly supports wireless power transfer for drones, then bidirectional power capability is achieved, but battery stress and degradation are exacerbated

Engineering Contradiction:

Improvebidirectional power capabilityVSAvoidbattery lifetime

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The supercapacitor bank serves as an intermediary for wireless power transfer operations. It handles the high-power pulses required for drone charging and discharging, protecting the battery from direct exposure to these stressors while enabling bidirectional power flow capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The supercapacitor bank is designed to perform multiple functions: it handles pulsed loads from compressor cycling, captures regenerative braking energy, and supports wireless power transfer for drones. This multi-functionality allows a single component to address diverse power management requirements without increasing battery stress.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system extends battery life, reduces sensitivity to temperature variations, and enables the transport vehicle to act as a mobile bidirectional power station for drones, enhancing operational range and feasibility by managing pulsed power loads efficiently and supporting wireless charging.

Implementation Method 1

a bidirectional DC/DC converter: (i) the bidirectional DC/DC converter, in order to regulate a pulsed power applied to the battery, configured to either: (1) transfer power to the super capacitor bank in order to absorb power from the load; or (2) transfer power from the super capacitor bank in order to supply power to the load

Methodology Applied

Scientific EffectElectrical power conversion:

Implementation Method 2

a super capacitor bank comprising a plurality of capacitors

Methodology Applied

Scientific EffectCapacitance: Capacitance

Implementation Method 3

a hybrid controller: (i) the hybrid controller, in order to minimize power transients on the battery, configured to identify: (1) when pulsed power is required to the load and instructing the bidirectional DC/DC converter to supply power to the load from the super capacitor bank

Methodology Applied

Scientific EffectPower transient detection:

Data Source

PatentUS11951849B2Hybrid power management system and method for delivering power in a transport vehicle

Publication Date: 2024.04.09 ELECTRO STANDARDS LAB

AI summary

Disclosed is a system configured to deliver power to a load in a transport vehicle, the system having: (a) a battery; (b) a super capacitor bank; (c) a bidirectional DC/DC converter configured to transfer power to/from the super capacitors in order to absorb/supply power from/to the load, and configured to transfer power between the super capacitors and the battery and/or the load in order to charge the super capacitor from the battery or load or charge the battery/load from the super capacitors in a controlled way (d) a hybrid controller, the hybrid controller configured to identify when pulsed power is required to/from the load and instructing the DC/DC converter to supply/absorb power to/from the load from/to the super capacitor bank and to identify when power needs to be transferred between the super capacitor and the battery/load to charge or discharge the battery/load and/or super capacitor.