Smart Battery Pack Control for Mixed-Type Discharge Continuity
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Solution Overview
Problem
Conventional inverter systems for power tools are limited to single-type battery packs connected in series, making them unusable if any battery pack is removed or fails, restricting flexibility and efficiency in power supply.
Innovation Solution
A smart battery control method using a microcontroller to determine the type of battery packs and configure discharge modes, allowing for series connections of remaining packs to ensure continuous power supply, prioritizing discharge based on energy levels and pack types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If single-type battery packs are connected in series to power the inverter, then the system operates reliably with a fixed configuration, but the system becomes unusable if any battery pack is removed or fails, reducing adaptability
Solution Approach 1:
The control method enables the power supply module to universally accept different battery pack configurations (single-type or mixed-types, different voltages) by implementing intelligent detection and adaptive discharge mode selection, making the system multi-functional in handling various battery scenarios
Solution Approach 2:
The system dynamically adjusts its operation by detecting battery pack types and states, then automatically selecting appropriate discharge modes (first discharge mode for normal operation, second discharge mode for abnormal conditions), enabling the system to adapt its configuration in real-time
2Device complexity
If all battery packs must be of the same type and in normal state to discharge power, then the system maintains simple control logic, but the system cannot operate if any battery pack fails or is removed, reducing productivity
Solution Approach 1:
The control method segments the battery packs into different groups (normal state packs and abnormal state packs) and implements different discharge strategies for each group, allowing the system to continue operating with available battery packs while isolating faulty ones
Solution Approach 2:
The system continuously monitors battery pack states and provides feedback to the control logic, which then adjusts the discharge mode accordingly, enabling the system to respond to changing battery conditions and maintain operation when possible
3Reliability
If the system requires all battery packs to be in normal state for discharge, then the system ensures safe operation, but the system cannot utilize available battery capacity when some packs are abnormal, increasing energy loss
Solution Approach 1:
The control method extracts and isolates the abnormal battery packs from the discharge circuit while continuing to utilize the normal battery packs for power supply, allowing the system to remove only the problematic components while maintaining operation with the remaining functional packs
Solution Approach 2:
The system changes operational parameters by switching between different discharge modes based on battery pack states, adjusting the discharge configuration to match the available healthy battery capacity and thereby reducing energy loss from unused battery resources
Data Source
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AI summary
The present invention proposes a method of smart battery control for a power supply module, where the power supply module includes a plurality of battery packs having at least a first type or second type battery pack, the method includes checking whether all battery packs are in a normal state that can be discharged and can be categorized into the first type battery pack, if yes, the power supply module discharges power by a first discharge mode; otherwise, neglecting the abnormal battery packs and forming series-connected battery pack units among the remaining battery packs, the power supply module discharging power by a second discharge mode; calculating electric energy of all battery packs, comparing the electric energy of individual series-connected battery pack unit, and scheduling the discharge priority among the series-connected battery pack units.