Multi-Battery Pack System with Modular SOC Re-scaling
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Solution Overview
Problem
Existing battery pack systems face issues with uneven lifespan and malfunction when replacing individual battery modules, leading to accelerated deterioration and limited space efficiency due to standardized battery forms, requiring entire pack replacement and limiting application scenarios.
Innovation Solution
A battery pack system with a control unit that manages multiple battery modules of varying capacities, forms, and lifespans, allowing for easy replacement and re-scaling of state of charge (SOC) to maintain uniformity, and incorporating DC/DC converters for parallel connections to standardize outputs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If battery modules with the same form and performance are used, then control is simplified, but space efficiency and adaptability are reduced
Solution Approach 1:
The battery pack is divided into multiple independent battery modules that can be individually replaced. Each module has standardized interfaces allowing different forms and capacities while maintaining uniform control through modular architecture. This segmentation enables mixing of different battery types (e.g., 18650, 21700 cells) within the same pack without requiring uniformity across all modules.
Solution Approach 2:
The control device is designed with universal functionality to manage battery modules with varying capacities, forms, and lifespans. The control system includes a capacity database that stores information about different battery types and automatically adjusts charging/discharging parameters to accommodate heterogeneous modules, making the control system adaptable to multiple battery configurations.
2Ease of manufacture
If standardized battery forms are used, then manufacturing is simplified, but space efficiency and energy density are reduced
Solution Approach 1:
The battery pack structure is segmented into standardized module units with uniform mounting interfaces. This allows different battery cell forms (18650, 21700, pouch cells) to be installed in the same module type, maintaining manufacturing simplicity while enabling flexible spatial arrangement to maximize space utilization.
Solution Approach 2:
Different regions of the battery pack can accommodate different battery forms and capacities based on local space requirements. The pack design allows optimization of energy density in specific areas by selecting appropriate battery types for each location, rather than using uniform batteries throughout.
3Ease of repair
If individual battery modules are replaced, then maintenance is improved, but lifespan uniformity and reliability are worsened due to capacity differences
Solution Approach 1:
The battery pack is divided into independently replaceable modules with standardized electrical and mechanical interfaces. This segmentation enables individual module replacement without affecting other modules, improving ease of repair while maintaining overall pack reliability through proper module matching during replacement.
Solution Approach 2:
The control device continuously monitors the state of charge, temperature, and health of each battery module. Based on this feedback, the system identifies modules that have reached end-of-life and schedules their replacement. The control device also tracks the capacity of replaced modules to ensure proper matching with new modules, maintaining lifespan uniformity across the pack.
Solution Approach 3:
The control device adjusts charging and discharging parameters dynamically based on the capacity and health state of individual modules. When modules with different capacities are present, the control system modifies current and voltage parameters to ensure uniform aging rates and extend the overall pack lifespan, preventing premature failure of weaker modules.
4Reliability
If entire battery packs are replaced, then reliability is restored, but cost and resource waste increase
Solution Approach 1:
The battery pack is designed as an assembly of interchangeable modules, allowing replacement of only the faulty module rather than the entire pack. This segmentation enables selective replacement, restoring reliability while minimizing resource waste by retaining functional modules.
Solution Approach 2:
When a battery module reaches end-of-life or fails, it is identified and replaced individually while the remaining functional modules are retained and continue to operate. The control device manages the transition by reconfiguring the pack operation to accommodate the new module mixture, thereby recovering and reusing valuable resources.
Data Source
AI summary
The present invention relates to a battery pack system. In the battery pack system including a multi-battery according to the present invention, replacement may be easily performed in a lower unit of the battery pack system, the battery pack system including a multi-battery may include the battery modules having various forms and performances and capable of being arranged so as to increase space efficiency of the battery pack system, the battery pack system including a multi-battery includes the battery modules having various forms and performances, such that an energy density of the battery pack system may be improved, and the battery pack system including a multi-battery may allow battery modules having various performances and outputs to maintain states of charge (SOCs) (%) in a uniform ratio by estimating the SOCs of the respective battery modules and re-scaling the SOCs according to a capacity criterion of a control unit.