Programmable Battery Pack Reconfiguration for Lightweight Power Control

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Solution Overview

Problem

Existing solar and battery power systems for high-altitude, long-endurance aircraft introduce additional weight and complexity due to maximum power point trackers and battery packs.

Innovation Solution

A reconfigurable battery system with switchable battery modules and a battery pack controller that adjusts the series connection of battery modules based on state of health, open circuit voltage, internal resistance, state of charge, and closed circuit voltage to achieve a predetermined target output voltage, using solid-state switches for efficient power management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If maximum power point trackers and battery packs are used in solar-powered aircraft, then power management capability is improved, but system weight and complexity increase

Engineering Contradiction:
Improvepower management capabilityVSAvoidsystem complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The battery pack is divided into multiple individually controllable battery modules, each with its own solid-state switch. This segmentation allows the controller to selectively connect or bypass specific modules based on their state of charge, enabling flexible power management without requiring complex external circuitry.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The battery pack configuration is made dynamic through real-time monitoring of each module's voltage and automatic reconfiguration of the series/parallel connections. The system adapts its internal structure based on operating conditions, eliminating the need for external maximum power point trackers while maintaining optimal power management.

Inventive Principle:
Principle #15Dynamics

2Productivity

If maximum power point trackers are used in solar-powered aircraft, then power optimization is improved, but system weight increases

Engineering Contradiction:
Improvepower optimizationVSAvoidsystem weight
Core Design Contradiction:
ProductivityVSWeight of moving object

Solution Approach 1:

The maximum power point tracking function is extracted from external circuitry and integrated directly into the battery pack's control system. The controller performs MPPT calculations and uses the battery module switches to implement power optimization, eliminating the need for separate tracker hardware and reducing overall system weight.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The battery pack controller is designed to perform multiple functions simultaneously: it monitors battery state, manages charge/discharge operations, performs maximum power point tracking, and dynamically reconfigures the battery architecture. This multi-functionality consolidates what would traditionally require separate systems into a single integrated unit, reducing weight.

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

Data Source

PatentUS20250329809A1Programmable battery pack
Publication Date: 2025.10.23 AURORA FLIGHT SCIENCES CORP
  • US20250329809A1 patent drawing
  • US20250329809A1 patent drawing
  • US20250329809A1 patent drawing

AI summary

The present disclosure relates to a reconfigurable battery system and method of operating the same. An example apparatus includes at least one memory, instructions in the apparatus, and processor circuitry to execute the instructions to determine a state of charge of a battery, determine a closed circuit voltage of the battery, determine a value of a parameter based on a ratio of the state of charge and the closed circuit voltage, and control a switch coupled to the battery based on the value of the parameter, the controlling of the switch to either cause the battery to be coupled to a battery string or cause the battery to be disconnected from the battery string.