Stackable Battery Emulator With Isolated Cell Voltage Replication
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Solution Overview
Problem
Conventional battery pack development and testing require the use of real batteries, which pose risks of fire, explosion, and electrical shock, and are costly and time-consuming due to the need for specialized laboratory equipment.
Innovation Solution
A battery emulator system with a single input voltage source, adjustable voltage regulators, and voltage isolation circuitry to replicate battery cell voltages, allowing for safe and cost-effective testing of battery software, firmware, and circuitry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If real battery packs are used for development and testing, then testing accuracy is improved, but safety risks (fire, explosion, electrical shock) increase
Solution Approach 1:
The patent creates a virtual copy of the battery pack using software simulation and circuit emulation. The battery emulator circuitry replicates the electrical characteristics of real battery cells through voltage regulation and control algorithms, allowing testing of battery management systems without physical battery risks. This copying approach maintains testing accuracy while eliminating fire and explosion hazards associated with real lithium-ion batteries.
Solution Approach 2:
The patent introduces a battery emulator as an intermediary device between the test equipment and the battery management system. This emulator circuit includes voltage regulators, control logic, and isolation components that mediate the testing process, providing the electrical characteristics of real batteries while preventing direct exposure to dangerous battery conditions. The intermediary protects users from electrical shock and thermal runaway risks.
2Adaptability or versatility
If multiple isolated adjustable power supplies are used for battery testing, then testing capability is improved, but cost and device complexity increase
Solution Approach 1:
The patent merges multiple power supply functions into a single integrated battery emulator device. The emulator combines voltage regulation, current control, isolation, and simulation capabilities in one circuit architecture. This consolidation provides the same testing versatility as multiple isolated power supplies while reducing overall system complexity, component count, and cost. The unified design uses shared control logic and integrated circuitry to achieve multi-functionality.
Solution Approach 2:
The battery emulator is designed as a universal testing device that can simulate various battery configurations (single cell, multi-cell series/parallel arrangements) and operating conditions through software control. The single device replaces multiple specialized power supplies by providing adjustable voltage, current, and isolation characteristics programmatically. This multi-functionality achieves the same testing capability with reduced device complexity and lower cost.
3Reliability
If conventional battery testing methods are used, then comprehensive testing is achieved, but time and expense increase
Solution Approach 1:
The battery emulator performs preliminary setup and configuration through software programming before physical testing begins. Test parameters, battery characteristics, and test sequences are pre-configured in the control logic, eliminating time-consuming manual adjustments during testing. The emulator pre-establishes the electrical model of the battery, allowing immediate commencement of comprehensive tests without lengthy preparation of multiple power supplies.
Solution Approach 2:
The patent enables rapid parameter changes through software control of the emulator circuitry. Test conditions such as voltage levels, current rates, and load characteristics can be modified instantly by changing control parameters rather than physically reconfiguring multiple power supplies. This digital parameter adjustment maintains comprehensive testing capability while dramatically reducing the time and expense associated with conventional manual testing procedures.
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 reduces the risk of fire and shock while lowering costs and time, enabling efficient simulation of multiple battery cell configurations with virtual grounding and isolation, facilitating faster product development.
Implementation Method 1
an adjustable voltage regulator. The battery emulator further includes a user control device coupled to the adjustable voltage regulator and configured to control an output of the adjustable voltage regulator
Implementation Method 2
voltage isolation circuity which isolates the input voltage and/or output voltage from an adjustable voltage regulator, preventing them from interfering with the user control device
Data Source
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AI summary
The present invention is a battery emulator that permits the development and testing of battery software, firmware, and/or circuitry with lowered risk of shock, explosion, fire, or other dangerous conditions. The battery emulator includes a single input voltage source that provides an input voltage to an adjustable voltage regulator. The battery emulator further includes a user control device coupled to the adjustable voltage regulator and configured to control an output of the adjustable voltage regulator, wherein the output of an adjustable voltage regulator is configured to replicate an output voltage of a single battery cell of a multi-cell battery. The battery emulator further includes voltage isolation circuity which isolates the input voltage and/or output voltage from an adjustable voltage regulator, preventing them from interfering with the user control device.