Rechargeable Battery Testing With Opposition-Battery Buffering

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Solution Overview

Problem

Existing rechargeable battery testing systems require high-capacity electrical grid connections, which are not always available, and existing systems may not efficiently simulate extreme operating conditions, leading to inefficiencies and potential damage during testing.

Innovation Solution

A system comprising a power cycler, an opposition battery, and controllers that allow for testing rechargeable batteries using a lower-rated grid connection by incorporating an opposition battery to manage higher current demands, simulating extreme conditions through pulse and cycle tests.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If existing testing systems are used to simulate extreme operating conditions, then testing accuracy is improved, but the risk of battery damage increases

Engineering Contradiction:
Improvetesting accuracyVSAvoidbattery damage risk
Core Design Contradiction:
Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The system implements beforehand cushioning by using a power cycler with controlled current output and opposition batteries to buffer extreme conditions during testing. The power cycler gradually applies load and the opposition batteries absorb excess energy, preventing direct exposure of the battery under test to potentially damaging extreme conditions while still achieving accurate degradation assessment.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The power cycler acts as an intermediary between the grid connection and the battery under test. It mediates the extreme operating conditions by controlling current flow, using opposition batteries to simulate extreme conditions indirectly, and monitoring parameters in real-time, thereby achieving accurate testing without directly exposing the battery to harmful extreme conditions.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Productivity

If high-capacity grid connections are used for battery testing, then testing capability is improved, but infrastructure requirements worsen

Engineering Contradiction:
Improvetesting capabilityVSAvoidinfrastructure requirements
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The power cycler serves as an intermediary device that decouples the battery testing capability from direct grid connection capacity. It uses opposition batteries to amplify or reduce the effective testing capacity, allowing high-capacity testing to be performed through medium-capacity grid connections by managing current flow and energy storage dynamically.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The system changes the electrical parameters (voltage, current, power) dynamically during testing by using opposition batteries in series or parallel configurations and adjusting power cycler output. This allows the same physical infrastructure to support varying testing capacities, effectively enabling high-capacity testing without requiring proportionally high-capacity grid connections.

Inventive Principle:
Principle #35Parameter changes

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

Enables efficient testing of rechargeable batteries under simulated extreme conditions without requiring high-capacity grid connections, providing accurate degradation assessment and reducing the risk of damage.

Implementation Method 1

The power cycler is configured to inject a predetermined amount of current into the rechargeable battery and measure a voltage across the rechargeable battery in response to the injected current

Methodology Applied
Scientific EffectElectrical energy transformation:

Implementation Method 2

The opposition battery is connected in opposition to the rechargeable battery between the rechargeable battery and the power cycler

Methodology Applied
Scientific EffectBattery energy storage and release: Battery (electricity)

Data Source

PatentUS20250306120A1System and methods for testing of a rechargeable battery
Publication Date: 2025.10.02 COX AUTOMOTIVE INC
  • US20250306120A1 patent drawing
  • US20250306120A1 patent drawing
  • US20250306120A1 patent drawing

AI summary

System and method for testing of a rechargeable battery is provided. The system includes a power cycler having a negative terminal and a positive terminal. The rechargeable battery includes a negative terminal and a positive terminal. The negative terminal of the rechargeable battery is connected to the negative terminal of the power cycler. An opposition battery includes a negative terminal and a positive terminal. The positive terminal of the opposition battery is connected to the positive terminal of the rechargeable battery. The negative terminal of the opposition battery is connected to the positive terminal of the power cycler. The power cycler is configured to inject a predetermined amount of current to the rechargeable battery.