Modular Battery Cell Test System for Virtual Pack Verification
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Solution Overview
Problem
Existing battery cell testing and battery pack verification systems face challenges in efficiently testing large numbers of battery cells, grouping cells with similar characteristics, and addressing reliability issues such as battery explosions and uneven lifespan.
Innovation Solution
A modular battery cell test and battery pack verification system that includes cell test modules, a main control unit, and a main battery, allowing for the testing and grouping of battery cells, creation of virtual battery packs, and energy recovery to reduce testing costs and improve efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional battery cell testing systems are used, then testing can be performed on individual cells, but the system cannot efficiently test large numbers of cells simultaneously or group them by characteristics
Solution Approach 1:
The testing system is divided into multiple independent test modules (first test module, second test module, etc.), each capable of testing individual battery cells. These modules can be independently configured and operated, allowing parallel testing of multiple cells while maintaining manageable complexity through modular architecture.
Solution Approach 2:
Each test module is designed with universal functionality to perform multiple types of tests (capacity testing, charge-discharge cycles, characteristic measurement) on different battery cells. The modules can be configured through control signals to perform various testing operations, making the system adaptable to different testing requirements without requiring separate dedicated equipment for each function.
2Measurement precision
If battery cells are tested individually and then manually grouped, then testing accuracy is maintained, but labor costs and time consumption increase significantly
Solution Approach 1:
The system performs preliminary characteristic measurements on all battery cells during the initial testing phase. Test modules measure capacity, internal resistance, and other characteristics, and the control unit stores this data. This preliminary action enables automatic grouping later without requiring additional manual measurement time.
Solution Approach 2:
The control unit receives test results from all modules, processes the data, and automatically generates grouping assignments based on measured characteristics. The system provides feedback by comparing cell parameters against target specifications and automatically determining which cells should be grouped together, eliminating manual judgment and reducing grouping time while maintaining measurement precision.
3Reliability
If virtual battery pack verification is performed, then actual battery pack conditions can be simulated, but the system requires complex connection configurations
Solution Approach 1:
The system creates a virtual battery pack by connecting test modules in series and parallel configurations that replicate actual battery pack architectures. Instead of assembling physical battery packs for testing, the system uses electrical connections between test modules to simulate pack behavior, maintaining verification reliability while avoiding the complexity of physical assembly and disassembly.
Solution Approach 2:
The connection configuration between test modules is dynamically adjustable through control signals. The system can reconfigure modules between series and parallel connections based on the virtual pack configuration being tested, allowing flexible simulation of different battery pack arrangements without physical reconfiguration or complex manual wiring changes.
4Productivity
If power is supplied from external sources during testing, then testing can proceed, but energy is wasted without recovery
Solution Approach 1:
During charge-discharge testing, the system recovers energy that would otherwise be dissipated. When battery cells are discharged during testing, the test modules capture the discharged energy and feed it back to power other test modules or store it in the main battery. This recovery mechanism reduces overall power consumption and improves testing efficiency by utilizing otherwise wasted energy resources.
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 enables efficient testing and grouping of battery cells, simulates actual battery pack conditions, and recovers energy used during testing, thereby improving the reliability of battery packs and reducing costs associated with labor and equipment.
Implementation Method 1
a main battery for supplying power to said cell battery test apparatus or recovering power discharged from said cell battery test apparatus
Data Source
AI summary
A modular battery cell test and battery pack verification system and method are disclosed. A modular battery cell test and battery pack verification system according to one embodiment of the present invention, for testing a battery cell and verifying a battery pack, comprises a cell battery test apparatus comprising a plurality of cell test modules for performing tests on single battery cells, and for performing verification on a virtual battery pack in connection with said cell test modules; a main control unit for transmitting control signals for test and verification to said cell test modules; and a main battery for supplying power to said cell battery test apparatus or recovering power discharged from said cell battery test apparatus.