Single-Stage Battery Charger With Integrated Multi-Battery Balancing
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Solution Overview
Problem
High-voltage and high-power AC-DC systems with multiple batteries require a large number of power converters and switching devices, leading to increased complexity, cost, and decreased reliability and efficiency.
Innovation Solution
A single-stage charger/balancer system that integrates multiple converters into a single unit, using switching bridges, transformers, and rectifier/chargers to reduce the number of switching devices required, with a controller managing the operation to deliver AC and DC voltages for charging and balancing between batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple power converters and switching devices are provided for each battery in a multi-battery system, then each battery can be charged independently with dedicated control, but the system complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple independent power converters into a single integrated converter that can serve multiple batteries simultaneously. The converter includes a single switching network with multiple output terminals that can be connected to different batteries, allowing one converter to perform the functions of what would traditionally require multiple separate converters.
Solution Approach 2:
The integrated converter is designed with multi-functionality to handle charging of multiple batteries with different voltage levels and requirements. The switching network can be configured to provide dedicated charging to any battery or simultaneous charging to multiple batteries, making a single device universal for multiple charging tasks.
2Ease of operation
If separate charging systems are provided for each battery, then independent charging control is achieved, but the number of switching devices increases leading to decreased efficiency
Solution Approach 1:
Multiple switching devices from separate converters are merged into a single switching network with fewer total switching elements. The network uses shared components and coordinated switching to achieve independent battery control while reducing the overall switching device count and associated energy losses.
3Reliability
If multiple independent charging systems are used, then each battery receives dedicated power conversion, but the system cost increases due to more components
Solution Approach 1:
The patent merges multiple independent charging systems into a single integrated charging system that maintains the ability to charge batteries independently. By combining power conversion components, control circuits, and switching devices into one unit, the total component count and manufacturing cost are reduced while preserving charging independence through configurable output connections.
4Power
If a high number of power converters are provided for high voltage batteries, then adequate power conversion capacity is ensured, but the system complexity and component count increase
Solution Approach 1:
The integrated converter is designed with universal capability to provide adequate power conversion for high voltage batteries. The switching network can be configured to deliver full power conversion capacity to any connected battery, and the single device can handle multiple batteries simultaneously, reducing the number of high-power converter units needed.
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
This solution reduces the complexity and cost of the system while improving reliability and efficiency by integrating charger and balancer functions into a single unit, effectively managing voltage conversions for multiple batteries.
Implementation Method 1
at least one transformer having two or more primary windings connected in series and coupled to the at least first and second switching bridges, the transformer further comprising at least two secondary windings
Data Source
AI summary
A charger for a battery power system can include first and second switching bridges with inputs couplable to an AC source, at least one transformer having two or more primary windings (connected in series and coupled to the switching bridges) and at least two secondary windings, and second rectifier/chargers, each coupled to at least one of the secondary windings and couplable to at least one battery. The switching bridges may be respectively operable during positive and negative half cycles of the AC source to deliver an AC voltage to the transformer. The rectifier/chargers may be operable in a first mode to receive an AC voltage from the transformer and deliver a DC voltage for charging the respective battery. In some multi-battery embodiments, the rectifier/chargers may also be operable in a second mode to deliver an AC voltage from a respective battery to the transformer to balance charge between the batteries.