Stackable Battery Emulator With Galvanic Isolation for Pack Testing
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Solution Overview
Problem
Conventional battery pack development and testing require the use of real batteries, posing risks of fire, explosion, and electrical shock, and are costly due to the need for multiple-output power supplies.
Innovation Solution
A battery emulator system with a single input voltage source, adjustable voltage regulators, and voltage isolation circuitry to replicate multiple battery cell voltages, allowing safe and cost-effective testing of battery software, firmware, and circuitry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If real battery packs are used for development and testing, then accurate battery performance testing is achieved, but the risk of fire, explosion, and electrical shock increases
Solution Approach 1:
The patent creates a safe copy of the battery pack by using a battery emulator that replicates the electrical characteristics and behavior of real battery cells. The emulator includes voltage regulators configured to simulate multiple battery cell voltages, allowing developers to test battery management systems, charging algorithms, and protection circuits without using actual battery packs, thereby eliminating fire and explosion risks while maintaining testing accuracy
Solution Approach 2:
The battery emulator acts as an intermediary device between the developer and the real battery pack. It provides a safe interface that mimics the electrical properties of real batteries, allowing testing of battery management systems without direct exposure to the hazards of real battery operation. The emulator includes isolation circuitry and controlled voltage sources that mediate the interaction between testing equipment and the simulated battery system
2Reliability
If multiple-output power supplies are used to replicate battery cell voltages, then accurate voltage simulation is achieved, but the cost and device complexity increase
Solution Approach 1:
The patent combines multiple voltage regulation functions into a single integrated battery emulator device. Instead of requiring separate power supplies for each battery cell voltage, the emulator uses multiple voltage regulators coupled to a single input voltage source, with each regulator configured to provide the appropriate voltage for a specific battery cell. This merging approach reduces device complexity while maintaining accurate voltage simulation for multiple cells
Solution Approach 2:
The battery emulator is designed as a universal device that can simulate various battery pack configurations. The voltage regulators can be configured to replicate different numbers of battery cells and voltage levels, allowing a single device to perform multiple testing scenarios. This multi-functionality eliminates the need for multiple specialized power supplies while maintaining accurate voltage representation for different battery pack arrangements
3Ease of operation
If isolated adjustable laboratory power supplies are purchased for each battery cell, then independent voltage control is achieved, but the expense increases
Solution Approach 1:
The patent merges the functionality of multiple isolated adjustable power supplies into a single battery emulator device. Each voltage regulator within the emulator provides independent voltage control for its associated battery cell simulation, while all regulators share a common input voltage source. This consolidation reduces the quantity of power supplies from multiple separate units to a single integrated device, thereby reducing expense while maintaining independent voltage control capability
Data Source
AI summary
The present disclosure 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 may include 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 circuitry which isolates the input voltage and/or output voltage from an adjustable voltage regulator, preventing them from interfering with the user control device.