Synchronous Transformer Windings for Precise Lithium Battery Equalization
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Solution Overview
Problem
Existing transformer winding structures for lithium battery packs suffer from inconsistencies in coil turns and inductance, leading to inaccurate battery equalization, with a voltage equalization accuracy of only 20 mV, which is insufficient for effective battery equalization.
Innovation Solution
The implementation of a multiple integrated synchronous winding structure, where N first windings and N second windings are wound with the same number of coil turns and connected in parallel with switches, ensuring high consistency in coil turns and inductance, thereby enhancing battery equalization precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If split asynchronous winding method is used, then manufacturing process is simple, but coil turns consistency is poor
Solution Approach 1:
The patent merges N separate secondary windings into a single integrated winding structure where N winding lines are combined into one strand and wound synchronously on the magnetic core. This combining approach ensures that all windings have identical coil turns and inductance values, resolving the consistency issue while maintaining manufacturing simplicity through the integrated winding process.
2Manufacturing precision
If multiple integrated synchronous winding is implemented, then coil turns consistency is improved, but device complexity increases
Solution Approach 1:
The patent segments the integrated winding into N distinct winding lines that are combined into one strand. Each winding line corresponds to a specific secondary winding, allowing for precise control and identification of each winding's parameters while maintaining the overall integrated structure. This segmentation enables precise manufacturing without excessive device complexity.
3Adaptability or versatility
If N secondary sub-windings are wound separately, then manufacturing flexibility is high, but inductance difference is large
Solution Approach 1:
The patent applies preliminary action by pre-combining N winding lines into a single integrated strand before the winding process. This preliminary combination ensures that all windings are subjected to the same winding conditions, tension, and positioning, thereby achieving consistent inductance values across all secondary windings while maintaining manufacturing flexibility through the integrated approach.
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 approach significantly reduces voltage differences between batteries, achieving precise battery equalization and extending the life of multi-string lithium battery systems.
Implementation Method 1
According to Faraday's electromagnetic induction principle, the induced electromotive force of each winding is positively related to the number of coil turns n of the winding
Data Source
AI summary
This present disclosure discloses a transformer. The transformer comprises a lithium battery pack, a transformer coil and 2N switches. The lithium battery pack comprises N single batteries connected in series. The transformer coil comprises a magnetic core, N first windings and N second windings. The N first windings combined into one strand, the N second windings combined into one strand, are then wound on the magnetic core respectively. The N first windings and the N second windings have same number of coil turns, same homonymous ends and same common ends. Two ends of each single battery are connected with one first of the first windings and one of the second windings in parallel respectively. Each first winding is connected with one switch in series. Each second winding is connected with one switch in series. N is a natural number greater than or equal to 1.