Multi-Battery Charger Architecture With Dynamic Master Voltage
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Solution Overview
Problem
Existing charging systems for rechargeable batteries are inflexible, inefficient, and require multiple dedicated chargers for different battery types, complicating maintenance and increasing energy consumption.
Innovation Solution
A charger system with a master DC-source providing a variable magnitude voltage to multiple DC/DC-converters, each converting to a desired output voltage for respective battery modules, optimizing power consumption by adjusting the master voltage based on estimated power consumption and current needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple dedicated chargers with different output voltages are used for different battery types, then each battery can be charged with its specific voltage requirement, but the device complexity and maintenance difficulty increase significantly
Solution Approach 1:
The charger system employs a universal master DC-source that can serve multiple DC/DC-converters with different output voltage requirements. This single multi-functional charger replaces what would traditionally require multiple dedicated chargers, thereby reducing device complexity while maintaining adaptability to charge different battery types with their specific voltage requirements.
Solution Approach 2:
The charging system is segmented into a master DC-source and multiple independent DC/DC-converters, each capable of handling specific battery types. This segmentation allows the master DC-source to provide a standardized input while the individual converters handle the diversity of output requirements, reducing the complexity at the master level while maintaining versatility at the converter level.
2Adaptability or versatility
If a single large AC/DC-converter with multiple DC/DC-converters is used to charge multiple battery types, then charging capability is provided, but energy efficiency decreases due to voltage mismatches and power losses
Solution Approach 1:
The master DC-source dynamically adjusts its output voltage based on the real-time charging requirements of connected batteries. By continuously adapting the voltage level to match the actual needs of the batteries being charged, the system minimizes voltage mismatches and reduces energy losses that would occur with fixed voltage operation.
Solution Approach 2:
The system incorporates feedback mechanisms where the master DC-source monitors the charging status and voltage requirements of connected batteries, then adjusts its output accordingly. This feedback loop ensures optimal voltage matching between the charger and batteries, thereby minimizing power losses and improving energy efficiency while maintaining multi-battery charging capability.
3Manufacturing precision
If dedicated chargers with fixed output voltages are used for each battery type, then charging precision is maintained, but the system becomes inflexible when different voltage requirements arise
Solution Approach 1:
The master DC-source is designed to change its output voltage parameter dynamically based on the charging requirements of different battery types. This parameter adaptability allows the system to maintain charging voltage precision for each specific battery type while simultaneously providing the flexibility to handle various voltage requirements, effectively resolving the contradiction between precision and adaptability.
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 efficiently charges battery modules with varying voltages and currents, reducing power consumption and improving energy efficiency by minimizing voltage drops and current imbalances.
Implementation Method 1
a master DC-source configured to provide a master voltage with a variable magnitude to a plurality of DC/DC-converters. Each DC/DC-converter in the plurality of DC/DC-converters is configured to provide an output voltage and an output current
Data Source
AI summary
A method (300) for charging battery modules (4) using a charger system (1). The charger system (1) comprises a master DC-source (2) configured to provide a master voltage with a variable magnitude to a plurality of DC/DC-converters (3). Each DC/DC-converter in the plurality of DC/DC-converters (3) is configured to provide an output voltage and an output current to charge a respective battery module (4). The method comprises: obtaining (310) a desired charging voltage for each battery module (4) connected to a respective DC/DC-converter in the plurality of DC/DC-converters (3); obtaining (320) a possible output current for each DC/DC-converter in the plurality of DC/DC-converters (3) connected to a respective battery module (4); determining (330) a magnitude of the master voltage in dependency of an estimated power consumption of at least two DC/DC-converters in the plurality of DC/DC-converters (3) connected to a respective battery module (4) if the at least two DC/DC-converter in the plurality of DC/DC-converters (3) connected to a respective battery module (4) would charge the respective connected battery modules (4) with the respective desired charging voltages and the respective possible output currents; and charging (340) the respective battery modules (4) connected to the at least two DC/DC-converter in the plurality of DC/DC-converters (3) with the respective desired charging voltages, with the respective possible output currents, and with the master DC-source (2) providing the master voltage with the determined magnitude.