Precharge Resistor Circuit for Parallel Battery Inrush Control

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Solution Overview

Problem

Existing power supply systems face issues with inrush currents and overcurrents due to voltage differences between connected power storage devices during system start-up, leading to inefficiencies and potential component damage.

Innovation Solution

A power supply system with parallel-connected power storage devices and processing circuits that include precharge and discharge mechanisms using precharge resistors and controlled switch configurations to manage voltage imbalances, preventing overcurrents and optimizing capacitor charging and discharging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If power storage devices are connected in parallel during system start-up, then system power capacity is improved, but inrush currents and overcurrents occur due to voltage differences between devices

Engineering Contradiction:
Improvesystem power capacityVSAvoidinrush current and overcurrent
Core Design Contradiction:
PowerVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by pre-charging the smoothing capacitor before connecting power storage devices in parallel. The processing circuit detects voltage differences and activates the precharge function, which charges the capacitor through a precharge resistor before parallel connection, thereby preventing inrush currents and overcurrents during system start-up while maintaining the power capacity benefits of parallel configuration

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent uses the smoothing capacitor as an intermediary element between power storage devices with different voltages. By charging this intermediary capacitor first through a precharge resistor, the system creates a buffer that prevents direct high-current flow between devices with voltage differences, thus resolving the contradiction between parallel connection benefits and harmful current effects

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If additional discharge resistors are added to manage voltage imbalances, then overcurrent prevention is improved, but device complexity and cost increase

Engineering Contradiction:
Improveovercurrent preventionVSAvoidnumber of discharge resistors
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies universality by making the precharge resistor serve multiple functions: it acts as a precharge resistor during system start-up to charge the smoothing capacitor, and simultaneously functions as a discharge resistor to discharge accumulated electric charges from both the smoothing capacitor and power storage devices. This eliminates the need for separate discharge resistors, reducing device complexity while maintaining reliable overcurrent prevention

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent implements self-service by enabling the precharge resistor to discharge its own accumulated electric charges as well as charges from other circuit components. The processing circuit controls the precharge resistor to discharge charges from both the smoothing capacitor and power storage devices, making the system self-managing without requiring additional dedicated discharge components

Inventive Principle:
Principle #25Self-service

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

The system effectively prevents overcurrents by managing voltage differences between power storage devices, ensuring smooth system start-up and shutdown processes while reducing the need for additional discharge resistors, thus maintaining system efficiency and component integrity.

Implementation Method 1

a first process of pre-charging a smoothing capacitor provided in the first load device by supplying electric power from the first power storage device to the first load device via a precharge resistor provided in the first processing circuit

Methodology Applied
Scientific EffectElectrical Resistance: Electrical Resistance

Implementation Method 2

a second process of discharging, via the precharge resistor, electric charges accumulated in the smoothing capacitor; and a third process of discharging, via the precharge resistor, electric charges accumulated in the first power storage device

Methodology Applied
Scientific EffectJoule Heating: Joule Heating

Data Source

PatentUS12556016B2Power supply system, and moving object including power supply system
Publication Date: 2026.02.17 HONDA MOTOR CO LTD
  • US12556016B2 patent drawing
  • US12556016B2 patent drawing
  • US12556016B2 patent drawing

AI summary

A first processing circuit of a power supply system can selectively perform: a first process of pre-charging a smoothing capacitor provided in a first load device by supplying electric power from a first power storage device to the first load device via a precharge resistor provided in the first processing circuit; a second process of discharging, via the precharge resistor, electric charges accumulated in the smoothing capacitor; and a third process of discharging, via the precharge resistor, electric charges accumulated in the first power storage device.