Multi-battery Charging Station Selective Sub-module Connection
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Solution Overview
Problem
Existing maintenance and support systems for all-electric aircraft are inadequate, as they require specialized charging solutions for battery systems with multiple sub-modules connected in parallel, necessitating a system that can selectively connect and charge battery sub-modules on a common power bus while preventing damage through metric-based selection and charging strategies.
Innovation Solution
A charger system that receives metrics for each battery sub-module, selects appropriate sub-modules for charging based on health, state of charge, and temperature, and configures them for safe connection to a common power bus using diodes or switches, employing constant current and constant cell voltage charging techniques with balancing and temperature management to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple battery sub-modules are connected in parallel to a common power bus for charging, then charging capacity and speed are improved, but the risk of damage and system complexity increase
Solution Approach 1:
The battery system is divided into multiple independent sub-modules, each with individual health metrics monitoring. The charger selectively connects specific sub-modules to the common power bus based on their health status, preventing damaged modules from compromising the entire system while maintaining high charging capacity through parallel connection of healthy modules.
Solution Approach 2:
The charger dynamically adjusts charging parameters (current, voltage) for each sub-module based on real-time health metrics such as state of charge, temperature, and cycle count. This parameter adaptation ensures optimal charging speed for healthy modules while preventing damage to modules with degraded health, resolving the contradiction between speed and safety.
2Productivity
If all battery sub-modules are charged simultaneously on a common power bus, then charging efficiency is improved, but damage to unhealthy sub-modules may occur
Solution Approach 1:
Different charging strategies are applied to different sub-modules based on their individual health qualities. Healthy sub-modules receive high-current fast charging, while modules with degraded health metrics receive reduced current or are excluded from charging. This local differentiation maintains overall charging efficiency while protecting vulnerable modules from damage.
Solution Approach 2:
The charger dynamically reconfigures which sub-modules are connected to the common power bus based on real-time health metric evaluation. Modules that degrade during operation can be dynamically disconnected, while new healthy modules can be added to the charging group. This dynamic adaptation allows the system to maintain high charging efficiency while continuously protecting against battery damage.
3Quantity of substance
If battery sub-modules with degraded health are included in charging, then full battery capacity is utilized, but the risk of failure and safety hazards increase
Solution Approach 1:
The system continuously monitors health metrics (state of charge, temperature, cycle count, voltage) of each sub-module and uses this feedback to make real-time decisions about which modules to connect to the common power bus. This feedback mechanism ensures that modules approaching dangerous thresholds are automatically excluded, maintaining safety while still utilizing the cumulative capacity of all healthy modules.
Solution Approach 2:
Before connecting sub-modules to the common power bus for charging, the charger performs preliminary health metric evaluation to identify and exclude modules with degraded health. This preliminary screening prevents unsafe modules from being included in the charging process, eliminating safety hazards before they can manifest while preserving the full capacity of pre-validated healthy modules.
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
Ensures safe and efficient charging of battery sub-modules, minimizing charging time and preventing damage by selecting suitable sub-modules and adjusting charging settings dynamically, thereby maintaining the health and performance of the battery system.
Implementation Method 1
one or more battery sub-modules to electrically connect to a common power bus using the plurality of metrics are selected from the plurality of battery sub-modules. The selected battery sub-modules are configured so that the selected battery sub-modules are electrically connected to the common power bus
Implementation Method 2
the selected battery sub-modules that are electrically connected to the common power bus are charged
Implementation Method 3
employing constant current and constant cell voltage charging techniques with balancing and temperature management to prevent damage
Implementation Method 4
temperature management to prevent damage
Data Source
AI summary
Battery sub-modules are selecting to electrically connect to a common power bus, including by: determining if a discharge-related fault indication for a given battery sub-module indicates that the given battery sub-module is in a discharge-related fault condition. If so, the given battery sub-module is excluded from the selected battery sub-modules such that said given battery sub-module is electrically disconnected from the common power bus. The selected battery sub-modules are configured so that the selected battery sub-modules are electrically connected to the common power bus; the selected battery sub-modules that are electrically connected to the common power bus are charged.