Modular Battery Charging System With Active Harmonic Filtering
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Solution Overview
Problem
Conventional battery chargers have low power factor and high total harmonic distortion, which stress the power grid and are not grid-friendly, limiting their efficiency and longevity.
Innovation Solution
A modular battery charging system with active filtering and inverter modules, connected via a data and power bus, that allows for autonomous operation, high power factor, and low current harmonic distortion, enabling efficient power conversion and bidirectional communication to optimize charging and grid interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional battery chargers use simple rectifier and power conversion stages, then device complexity is reduced, but power factor deteriorates and total harmonic distortion increases
Solution Approach 1:
The charger is divided into multiple independent modular power stages, each with its own control circuitry. This segmentation allows each module to be optimized for power factor correction and harmonic reduction while maintaining overall system simplicity through standardized interfaces and scalable architecture.
Solution Approach 2:
The patent employs advanced control strategies that dynamically adjust switching frequencies, duty cycles, and phase angles of the power conversion stages. These parameter changes enable active power factor correction and harmonic cancellation, improving power quality without requiring complex passive filtering components.
2Adaptability or versatility
If modular power stages are used in parallel, then charging capacity and adaptability are improved, but device complexity increases
Solution Approach 1:
Each modular power stage is designed as a universal building block capable of operating independently or in parallel with others. The standardized interfaces and identical architecture allow the system to adapt to different charging capacities by simply adding or removing modules, without requiring complex reconfiguration or specialized control logic for each configuration.
Solution Approach 2:
The control system automatically detects the number and configuration of connected power stages, then self-configures the parallel operation parameters. Each module autonomously synchronizes its switching waveform and power output with the others, eliminating the need for complex external coordination and reducing overall control complexity.
3Reliability
If advanced control circuitry is implemented, then charging optimization and battery longevity are improved, but device complexity and cost increase
Solution Approach 1:
The control circuitry continuously monitors battery voltage, current, and temperature parameters, then feeds this information back to the power conversion stages. This closed-loop feedback enables dynamic adjustment of charging profiles to optimize battery longevity while using simple, cost-effective sensing and control components rather than complex algorithms.
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 achieves a power factor of nearly 100% and current THD of less than 10%, reducing grid stress and enabling smart grid compatibility, while also providing sulfated battery recovery and frequency regulation capabilities.
Implementation Method 1
at least one inverter module coupled to a respective modular port to convert DC power from the at least one battery into AC power and provide the AC power back to the AC source
Implementation Method 2
the at least one inverter module may filter the input AC power by measuring input AC current harmonics and injecting harmonics of equal and opposite polarity to cancel the input AC current harmonics
Implementation Method 3
a power conversion stage that converts the incoming alternating current (AC) power to DC output
Data Source
AI summary
A system for charging at least one battery may include a power and data communication bus including a plurality of AC and DC power lines and data communication lines, and a plurality of modular ports coupled thereto. Charging power modules and an inverter module(s) may be coupled to respective modular ports of the power and data communication bus. A central controller may be configured to communicate with the charging power modules and the inverter module(s) through the data communication lines, identify the charging power modules and the inverter module(s) coupled to the modular ports, along with respective functions and power ratings associated therewith, and selectively control the charging power modules and the inverter module(s) based upon their identified functions and power ratings to charge the at least one battery via the DC power lines and provide AC power back to the AC source.