Parallel Battery Charging Voltage Control to Prevent Trickle Charging
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Solution Overview
Problem
Charging multiple lithium-ion battery packs in parallel can lead to uneven charging rates and activation of trickle charging due to charge protection switches, preventing timely charging and increasing the risk of damage, especially when using a single charger.
Innovation Solution
A charging apparatus that initially sets the charging voltage to the lowest voltage of the battery packs and incrementally adjusts based on current readings to minimize the risk of triggering trickle charging, using a voltage manager to control the charging process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple lithium-ion battery packs are charged in parallel using a single charger, then charging efficiency and time are improved, but uneven charging rates occur due to voltage differences between packs
Solution Approach 1:
The charging voltage is dynamically adjusted based on real-time monitoring of battery pack voltages and currents. The system continuously adapts the charging parameters to maintain optimal charging conditions for all parallel-connected packs, resolving the contradiction between charging efficiency and uniformity.
Solution Approach 2:
The system changes charging parameters (voltage and current) based on the state of each battery pack. By monitoring voltage differences and adjusting charging current accordingly, the system ensures uniform charging across all packs while maintaining high charging efficiency.
2Loss of time
If charging voltage is increased to speed up charging, then charging time is reduced, but the risk of triggering trickle charging and battery damage increases
Solution Approach 1:
The system implements continuous feedback monitoring of battery voltage, current, and charge state. Based on this feedback, the charging voltage is dynamically adjusted to prevent overcharging and trickle charging activation, ensuring battery safety while minimizing charging time.
Solution Approach 2:
The system performs preliminary monitoring and assessment of battery pack states before initiating charging. By pre-evaluating voltage levels and charge conditions, the system can set appropriate initial charging parameters that prevent safety issues while optimizing charging speed.
3Reliability
If charging voltage is set to the lowest battery pack voltage, then all packs can be charged safely, but packs with higher voltage experience prolonged delays
Solution Approach 1:
The system applies different charging currents to different battery packs based on their individual voltage levels and charge states. Instead of using a uniform charging approach, each pack receives customized charging parameters, eliminating delays for higher-voltage packs while maintaining safety for all.
Solution Approach 2:
The charging system dynamically adjusts individual pack charging parameters based on real-time voltage and current measurements. This dynamic adjustment allows the system to optimize charging speed for each pack while preventing safety issues, resolving the contradiction between safety and charging delay.
4Reliability
If charge protection switches are used to prevent overcharging, then battery safety is improved, but trickle charging is triggered causing uneven charging rates and prolonged delays
Solution Approach 1:
The system replaces the mechanical charge protection switch mechanism with an electronic control system that continuously monitors and regulates charging current. This substitution eliminates the binary on/off nature of protection switches that cause trickle charging, allowing for smooth, continuous current adjustment that maintains both protection and charging efficiency.
Solution Approach 2:
The system uses continuous feedback from voltage and current sensors to regulate charging before protection switches are triggered. By maintaining charging parameters within optimal ranges through active control, the system prevents protection switch activation and its associated trickle charging mode, preserving both safety and charging rate.
Data Source
AI summary
A charging apparatus is provided according to some embodiments. The charging apparatus includes (1) charging circuitry configured to connect to a plurality of battery packs in parallel and (2) processing circuitry configured to control the charging circuitry by: (a) obtaining a voltage reading from each of the plurality of battery packs; (b) initially setting a charging voltage of a charger to a lowest voltage reading obtained from any of the plurality of battery packs; (c) while applying the charging voltage to the plurality of battery packs, obtaining a current reading from each of the plurality of battery packs that is charging; and (d) in response to the obtained current reading from a battery pack being below a minimum threshold current, increasing the charging voltage by a voltage step value. A similar method and computer program product are also provided.