Parallel Battery Formation Circuit for Balanced Series Testing

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Solution Overview

Problem

Current battery testing and formation methods are inefficient for large quantities of batteries, lacking precise measurement of current and capacity, and do not provide comprehensive functions like overcurrent protection and pre-equalization, especially when batteries have varying states of charge and health.

Innovation Solution

A circuit assembly and method using a parallel test management device (PTMD) with a main relay, current transducer, and auxiliary relay to connect batteries in parallel and series configurations, allowing for balanced current distribution and precise voltage control, enabling simultaneous testing and formation of multiple batteries with built-in protection and equalization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If batteries are tested individually using traditional methods, then measurement precision is maintained, but productivity is significantly reduced due to the need to test each battery separately

Engineering Contradiction:

Improvebattery testing throughputVSAvoidtesting system configuration

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system divides batteries into groups that can be connected in series or parallel configurations, allowing multiple batteries to be tested simultaneously while maintaining individual measurement capability through separate PTMD units for each battery

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The PTMD unit is designed as a universal module that can interface with any battery regardless of configuration, providing consistent measurement and control functions across individual, series, and parallel testing scenarios

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If multiple batteries are connected in parallel for simultaneous testing, then productivity increases, but current distribution balance becomes difficult to control

Engineering Contradiction:

Improvesimultaneous battery testing capacityVSAvoidcurrent distribution balance

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The PTMD incorporates real-time current sensing through current transducers that continuously monitor current distribution across parallel-connected batteries, enabling the control system to detect and correct imbalances by adjusting individual battery connections

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts the connection state of individual batteries through controllable switches, transitioning batteries between active testing and isolation states based on real-time performance monitoring to maintain optimal current distribution

Inventive Principle:

Principle #15Dynamics

3Reliability

If comprehensive protection functions are added to prevent overcurrent and overcharge, then reliability improves, but device complexity increases

Engineering Contradiction:

Improvebattery protection capabilityVSAvoidcircuit configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple protection functions including overcurrent protection, overcharge protection, and pre-equalization are integrated into a single PTMD unit, consolidating what would otherwise require separate circuitry into one unified device

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system implements automatic protection mechanisms that monitor battery parameters and autonomously activate protection functions without external intervention, with the PTMD detecting abnormal conditions and independently controlling switches to isolate affected batteries

Inventive Principle:

Principle #25Self-service

4Measurement precision

If extensive cabling and equipment are used for individual battery testing, then measurement precision is maintained, but loss of substance increases due to material consumption

Engineering Contradiction:

Improvecurrent and voltage measurement accuracyVSAvoidcabling and equipment material

Core Design Contradiction:

Measurement precisionVSLoss of substance

Solution Approach 1:

Multiple measurement and control functions are merged into integrated PTMD units, eliminating the need for separate cabling and equipment for each battery while maintaining measurement precision through shared high-accuracy sensors and control circuitry

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11933860B2System for forming and testing batteries in parallel and in series

Publication Date: 2024.03.19 ZHANG CHAOJIONG

AI summary

A circuit assembly for forming and testing batteries connected in parallel and in series includes a parallel test management device (PTMD) that connects to each battery and includes a main relay and a current transducer in series and an auxiliary relay in series with a current limiting resistor, which are parallel to the main relay. Parallel battery groups are formed by connecting multiple PTMD-battery combinations and a voltage equalizer in parallel. Multiple parallel battery groups are connected in series. A battery testing system (BTS) connects to the battery groups. The equalizers and the BTS pass current through the batteries simultaneously. The current through batteries and the voltage drop across the current transducer are about zero at the end of charge and discharge.