Multi-Stack Battery Connection Control for In-Rush Current Prevention
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Solution Overview
Problem
Existing energy storage systems (ESS) face inefficiencies due to unaccounted variations in resistance and capacity between battery stacks, leading to voltage discrepancies and potential damage from in-rush currents when connecting stacks, resulting in longer downtime and increased costs.
Innovation Solution
A multi-stack battery management system that includes a measurement module to measure voltage and current, an estimation system to calculate stack open circuit voltage and resistance, and a management module to determine safe connection to a shared DC bus, considering both ohmic and polarization resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery stacks with different resistance and capacity are connected to a shared DC bus, then the energy storage system can meet higher energy requirements, but large in-rush currents are generated which can damage the battery
Solution Approach 1:
The system performs preliminary measurements of voltage, current, and resistance for each battery stack before connection. The management module uses these pre-acquired data to predict in-rush current and determine safe connection timing, preventing damage before it occurs
Solution Approach 2:
The system continuously monitors voltage and current during operation and uses this feedback to dynamically determine when stacks can be safely connected. The management module adjusts connection decisions based on real-time system state, preventing harmful in-rush currents
2Productivity
If traditional approaches are used to manage battery stacks, then the system structure remains simple, but the downtime increases and cost increases due to needing to bring stacks to very similar voltage levels before connection
Solution Approach 1:
The system changes the connection criteria from requiring stacks to be at very similar voltage levels to allowing connection based on predicted in-rush current and resistance characteristics. This parameter change enables faster connection while maintaining safety
Solution Approach 2:
The management module automatically performs measurements, predictions, and connection decisions without manual intervention. The system self-manages the complex coordination of multiple stacks, reducing downtime while keeping the user interface simple
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
Enables safe and efficient connection of battery stacks with different state-of-health, allowing ESS to meet energy requirements while preventing damage from in-rush currents, and facilitating automatic stack connection during operation.
Implementation Method 1
a voltage measurement device configured to measure a measured voltage associated with one of the one or more stacks
Implementation Method 2
a current measurement device configured to measure a measured current associated with one of the one or more stacks
Implementation Method 3
generating an estimated stack open circuit voltage and an estimated stack resistance for one or more of the stacks
Data Source
AI summary
A multi-stack battery management device is disclosed herein. In various embodiments, the multi-stack battery management device comprises an energy storage system comprising one or more stacks including, wherein the one or more connected stacks comprises one or more connected stacks and one or more disconnected stacks, wherein the connected stacks are connected to a shared DC bus, a measurement module comprising a voltage measurement device and a current measurement device, the voltage measurement device configured to measure a measured voltage associated with one of the one or more stacks and the current measurement device configured to measure a measured current associated with one of the one or more stacks; a stack estimation system for receiving the measured voltage and the measured current from the measurement module and for generating an estimated stack open circuit voltage and an estimated stack resistance for one or more of the stacks; and a multi-stack management module for receiving the estimated stack open circuit voltage and the estimated stack resistance and for determining an output signal based on the estimated stack open circuit voltage and the estimated stack resistance, wherein the output signal is used for determining whether to connect the one or more disconnected stacks to the shared DC bus.