Utility Vehicle Battery Balancing for Safe Charge Transfer
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Solution Overview
Problem
Unregulated charge transfer between high power battery packs in utility vehicles can lead to high current transfer, potentially damaging the battery packs, necessitating a system to regulate and ensure safe energy transfer.
Innovation Solution
A control system using at least one electronic controller determines the state of charge of battery packs and initiates converter or direct battery balancing through a DC-to-DC converter to discharge energy from more charged packs to less charged packs, ensuring safe and balanced energy distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If unregulated charge transfer is used between battery packs, then energy transfer speed is improved, but battery pack safety deteriorates due to high current damage
Solution Approach 1:
A control system acts as an intermediary between battery packs, regulating charge transfer through monitored state-of-charge comparisons and controlled discharge pathways. The controller mediates the energy transfer by activating specific discharge circuits based on battery pack conditions, preventing unregulated high current flow while maintaining efficient energy distribution.
2Device complexity
If direct battery balancing is used, then device complexity is reduced, but battery pack reliability deteriorates due to potential high current damage
Solution Approach 1:
The system dynamically selects between direct and converter-based balancing methods based on real-time battery pack conditions. The control system adjusts the balancing approach by comparing state of charge levels and determining the appropriate discharge pathway, transitioning between direct connection and converter-mediated transfer as needed to maintain safety while managing complexity.
3Reliability
If converter battery balancing is used, then battery pack safety is improved, but device complexity increases due to DC-to-DC converter requirements
Solution Approach 1:
The system applies different balancing qualities to different battery pack scenarios. Direct balancing is used when safety conditions permit (simpler local implementation), while converter-based balancing is activated when state of charge differences require controlled energy transfer (enhanced local safety). This localized approach to quality control optimizes the balance between safety and complexity for each specific balancing situation.
4Device complexity
If battery balancing is not performed, then device complexity is reduced, but productivity deteriorates due to reduced runtime
Solution Approach 1:
The control system performs preliminary assessment of battery pack states before operation, identifying packs with lower state of charge. By proactively initiating balancing operations before runtime-critical situations arise, the system ensures optimal energy distribution across all packs, maximizing available runtime without requiring complex real-time intervention systems.
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 effectively regulates energy transfer, preventing damage from high current and ensuring safe operation by balancing the state of charge among battery packs, thereby extending the runtime and lifespan of the utility vehicle.
Implementation Method 1
discharge the first battery pack to the second battery pack through a DC-to-DC converter
Data Source
AI summary
A battery balancing method for balancing voltages of battery packs on a bus bar of a utility vehicle is disclosed. The method includes determining, by a control system, a state of charge for a first battery pack and a second battery pack of the utility vehicle, initiating converter battery balancing, by the control system, to discharge the first battery pack to the second battery pack through a DC-to-DC converter in response the first battery pack having a state of charge that is more than a first threshold amount above a state of charge of the second battery pack, and initiating direct battery balancing, by the control system, to discharge the first battery pack to the second battery pack in response to the first battery pack having a state of charge that is less than the first threshold amount above the state of charge of the second battery pack.