Partial Failure Detection in Multi-Component Rechargeable Power Packs
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Solution Overview
Problem
Rechargeable power packs with multiple component batteries face issues when one battery fails, leading to over-current charging of the remaining battery, potential damage, and reduced operating time, as existing systems lack the ability to detect partial failures and adjust charging accordingly.
Innovation Solution
The system monitors unloaded and loaded voltages, charging current, impedance, and charge/discharge times to determine if a component battery has failed, allowing for corrective actions such as reducing charging current or halting charging, and provides user indications of partial failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If charging current is limited based on rated capacity, then battery safety is improved, but charging time increases when partial failure occurs
Solution Approach 1:
The system performs preliminary detection of battery component status before charging begins or during charging cycles. By monitoring voltage, current, and impedance characteristics, the system identifies functional batteries in advance and configures appropriate charging parameters, preventing both overcharging and unnecessary charging time extension
Solution Approach 2:
The charging current limit is made dynamic rather than fixed. The system continuously monitors battery pack composition and adjusts the maximum charging current based on the number of functional batteries detected. When all batteries are functional, full charging current is permitted; when partial failure is detected, the current limit is proportionally reduced to prevent overheating while maximizing charging speed for the remaining functional batteries
2Productivity
If maximum charging current is applied, then charging speed is improved, but risk of overheating and damage increases when batteries are partially failed
Solution Approach 1:
The system implements continuous feedback monitoring of battery parameters including voltage, current, temperature, and impedance during charging. When a change in impedance or voltage characteristics indicates battery failure, the system immediately adjusts the charging current downward to prevent overheating and damage to the remaining functional batteries, while still maintaining optimal charging speed within safe limits
Solution Approach 2:
The system changes charging parameters (current limit, voltage threshold) based on the detected number of functional batteries. When partial failure is detected through impedance monitoring, the charging current parameter is dynamically adjusted to a reduced level appropriate for the remaining functional batteries, preventing harmful overheating while maintaining efficient charging
3Reliability
If charging current is reduced after failure detection, then safety is improved, but operating time of device is reduced
Solution Approach 1:
The system detects battery failures and reconfigures charging parameters in advance before critical overheating occurs. By identifying functional batteries through impedance monitoring and proactively adjusting charging current limits, the system ensures safe charging while maximizing the energy stored in functional batteries, thereby extending device operating time despite the failure
Data Source
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AI summary
Systems and methods to detect a failure of a subset of component power packs within a multiple component rechargeable power pack. At least one parameter of a charging current that is provided for a time duration to a rechargeable power pack is determined (302). A measured capacity change quantity for the rechargeable power pack during the time duration is estimated (304). The measured capacity change quantity is compared, after the time duration, to an expected capacity change quantity that is based upon the at least one parameter (306). A determination is made that at least one component power pack within the rechargeable power pack has failed based on a difference between the measured capacity change quantity and the expected capacity change quantity (308). A charging current parameter is modified in response to the determining that the at least one component power pack has failed (312).