Modular Battery Charger Controller for Multi-Chemistry Adaptation
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Solution Overview
Problem
Manufacturers of medical and industrial devices face high costs due to the need for custom battery charger controllers for unique battery designs and revisions, as off-the-shelf chargers often fail to meet specific charging requirements.
Innovation Solution
A battery charger controller is developed using a modular approach with a main block, parallel blocks, and serial blocks, allowing for the creation of customizable charging profiles to accommodate various battery types and designs within a single controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a custom battery charger controller is designed for each unique battery design, then the charging requirements are met, but the development cost increases
Solution Approach 1:
The battery charger controller is designed with a programmable architecture that can be configured to support multiple battery chemistries and charging profiles. A single controller hardware platform can be programmed with different charging algorithms for Li-ion, Li-po, NiMH, and other battery types, eliminating the need for separate custom controllers for each battery design while maintaining reliable charging performance.
Solution Approach 2:
The controller uses programmable parameters and configurable settings that can be adjusted through software to accommodate different battery specifications. By changing programming parameters rather than hardware design, the same controller can adapt to various battery chemistries, capacities, and charging requirements, reducing development costs while meeting reliability requirements.
2Ease of manufacture
If an off-the-shelf battery charger controller is used, then the development cost is reduced, but the unique battery charging requirements are not met
Solution Approach 1:
The off-the-shelf controller is enhanced through programmable configuration that allows parameters such as charging voltage, current, temperature thresholds, and charging profiles to be adjusted to match unique battery requirements. This software-based customization enables a single controller to adapt to different battery chemistries and specifications without requiring custom hardware design.
Solution Approach 2:
The controller implements dynamic charging algorithms that can adjust charging parameters in real-time based on battery state, temperature, and specific chemistry requirements. This dynamic adaptability allows a standardized controller to meet unique charging requirements for different battery types through programmable control logic rather than fixed hardware design.
3Ease of manufacture
If a single battery charger controller is designed to charge multiple battery types, then the development cost is reduced, but the device complexity increases
Solution Approach 1:
The controller architecture is segmented into modular components, with separate charging algorithms and parameter sets for different battery chemistries. Each battery type has its own configurable profile that can be independently adjusted, allowing the controller to handle multiple battery types through organized, manageable segments rather than a monolithic complex design.
Solution Approach 2:
The controller uses template-based charging profiles that can be copied and customized for different battery types. Instead of designing unique control logic for each battery chemistry, standardized profile templates are created and then configured with specific parameters for Li-ion, Li-po, NiMH, and other battery types, reducing the perceived complexity through systematic reuse of proven charging algorithms.
Data Source
AI summary
Methods and systems are provided for a battery charging system. The methods and systems allow a user to charge a plurality of different battery types and configurations via a single battery charger.