1. A Pulse-Synchronized (PS) charging system (100) for lithium-ion batteries, the system (100) comprising: a battery pack (102), comprising a plurality of lithium-ion cells electrically connected in series, parallel, or a combination thereof, the battery pack (102) configured to store electrical energy and supply power; a charge control unit (104) connected to the system (100), the charge control unit (104) configured to regulate electrical power supplied to the battery pack (102) and to operate in multiple charging modes; a plurality of sensors (106) integrated with the battery pack (102), configured to continuously measure operating parameters of the battery pack (102) and generate corresponding sensor signals; a communication network (108) provided with the system (100), the communication network (108) being configured to transmit data between the several components of the system (100); a processing unit (110) operatively connected to the plurality of sensors (106) and the charge control unit (104), the processing unit (110) configured to dynamically adjust charging parameters based on real-time battery condition data, the processing unit (110) comprising: an input module (112) configured to receive measurement signals from the plurality of sensors (106) associated with the battery pack (102); a data processing module (114) configured to filter, condition, and convert the received measurement signals into processed battery condition data suitable for further analysis; a charge state estimation module (116) configured to determine a real-time state-of-charge (SoC) of the battery pack (102) based on the processed voltage and current data and to generate a charge state output representative of the energy level of the battery pack (102); an impedance estimation module (118) configured to estimate an internal resistance of the battery pack (102) using variations in measured voltage and current characteristics during charging operations; a charging mode selection module (120) configured to determine an appropriate charging mode from a plurality of charging modes based on the charge state output and the estimated internal resistance; a mode transition control module (122) configured to determine switching points between the constant-current mode, the pulse-based charging mode, and the constant-voltage mode based on at least one of a voltage gradient, a state-of-charge slope, and charging current characteristics; an adaptive pulse control module (124) configured to generate and dynamically adjust pulse charging parameters including pulse amplitude, pulse duration, and pulse interval in response to the real-time battery condition data; an output module (126) configured to generate control signals and transmit the control signals to the charge control unit (104) for regulating current and voltage supplied to the battery pack (102); and an user interface (130) linked with the output module (126), configured to display battery charging parameters including voltage, current, temperature, and state-of-charge (SoC), and to enable monitoring and control of the charging process.

2. The system (100) as claimed in claim 1, wherein a cloud database (128) is provided for storing historical battery charging data, operational parameters, and performance metrics.

3. The system (100) as claimed in claim 1, wherein the multiple charging modes including a constant-current (CC) charging mode, a pulse-based charging mode, and a constant-voltage (CV) charging mode.

4. The system (100) as claimed in claim 1, wherein the system (100) includes a power source (138), configured to provide electrical energy for charging a battery pack (102), the power source (138) comprising at least one AC or DC supply unit adapted to deliver regulated electrical power to a charging circuit.

5. The system (100) as claimed in claim 1, wherein the plurality of sensors (106) includes a voltage sensor, a current sensor, and a temperature sensor.

6. The system (100) as claimed in claim 1, the system (100) includes an isolation circuitry (132) linked to the sensors and processing unit (110), configured to separate the high-power battery charging circuit from the low-power control electronics to protect the system (100) and ensure that measurements are accurate and noise-free.

7. The system (100) as claimed in claim 1, wherein the system (100) includes a thermal management module (134) is configured to monitor temperature data from the temperature sensor and to limit charging current, modify pulse parameters, or initiate a cooling mechanism when the temperature exceeds a predefined safety threshold.

8. The system (100) as claimed in claim 1, the system (100) includes a feedback module (136) is configured to receive real-time measurements of battery parameters including voltage, current, temperature, and state of charge, and to dynamically adjust charging parameters including current level, pulse amplitude, pulse duration, and charging mode transition points based on the received measurements.

9. The system (100) as claimed in claim 1, wherein the adaptive pulse control module (124) calculates voltage gradient changes across charging intervals using a Pulse-Synchronized (PS) algorithm to determine optimal switching from pulse-controlled mode to constant-voltage mode.

10. A method (200) for charging a lithium-ion battery, the method comprising: supplying electrical power to a battery pack (102) through a charge control unit (104) configured to operate in multiple charging modes; sensing operating parameters of the battery pack (102) using a plurality of sensors (106), the operating parameters including at least voltage, current, temperature, and battery operating characteristics, and generating corresponding sensor signals; receiving the sensor signals at a processing unit (110) and processing the received sensor signals to obtain conditioned battery condition data; determining a real-time state-of-charge (SoC) of the battery pack (102) based on processed voltage and current data by a charge state estimation module (116); estimating an internal resistance of the battery pack (102) based on variations in measured voltage and current characteristics during charging by an impedance estimation module (118); selecting an appropriate charging mode from a plurality of charging modes including constant-current mode, pulse-based charging mode, and constant-voltage mode, based on the determined state-of-charge and estimated internal resistance by a charging mode selection module (120); determining switching points between the constant-current mode, the pulse-based charging mode, and the constant-voltage mode based on at least one of a voltage gradient, state-of-charge slope, and charging current characteristics by a mode transition control module (122); adjusting pulse charging parameters including pulse amplitude, pulse duration, and pulse interval based on real-time battery condition data by an adaptive pulse control module (124); generating control signals corresponding to the selected charging mode and pulse charging parameters and transmitting the control signals to the charge control unit (104) to regulate current and voltage supplied to the battery pack (102); and displaying battery charging parameters including voltage, current, temperature, and state-of-charge on a user interface (130) linked with the output module (126) to enable monitoring and control of the charging process.

Description:FIELD OF DISCLOSURE
[0001] The present disclosure generally relates to rechargeable energy storage devices, more specifically, relates to Pulse-Synchronized (PS) charging system for lithium-ion batteries that provides real-time adaptive control of charging modes. The system integrates multiple charging phases according to live feedback from battery parameters that optimizes charging efficiency and speed for lithium-ion battery.
BACKGROUND OF THE DISCLOSURE
[0002] Lithium-ion batteries (LIBs) are widely used in electric vehicles, portable electronics, and energy storage systems due to their high energy density, long cycle life, and relatively low self-discharge. Efficient and safe charging of lithium-ion batteries is a critical requirement for ensuring optimal battery performance, extended lifespan, and reliable operation in modern energy systems. Among the various charging strategies, the Constant Current–Constant Voltage (CC–CV) protocol is the most commonly adopted method in commercial battery management systems because of its simplicity and ease of implementation. In this method, the battery is initially charged at a constant current until a predetermined voltage limit is reached, after which the charging process continues at a constant voltage until the charging current gradually decreases to a predefined cutoff level.
[0003] However, conventional CC–CV charging techniques are limited in their ability to respond to dynamic changes occurring within the battery during charging. Lithium-ion batteries exhibit variations in internal parameters such as temperature, internal resistance, and state of charge (SoC) as the charging process progresses. Traditional charging protocols do not adequately adapt to these variations in real time. Due to uneven SoC distribution among cells, localized thermal hotspots, reduced energy efficiency, and accelerated capacity degradation may occur during repeated charging cycles. These issues are particularly critical in high-capacity battery packs used in electric vehicles, where maintaining thermal stability and uniform charging across multiple cells is essential for safety and long-term reliability.
[0004] Several alternative charging strategies have been investigated to overcome the limitations of conventional CC–CV methods. For instance, pulse charging techniques have been proposed to enhance ion diffusion and reduce polarization within battery electrodes. Similarly, Constant Power–Constant Voltage (CPCV) charging methods and machine-learning-based charging control strategies have been explored to improve charging efficiency and battery life. Despite these developments, many of these approaches remain limited to theoretical analysis or simulation studies and are not widely implemented in practical battery systems. Furthermore, existing charging systems often lack the capability to dynamically adapt charging parameters based on real-time sensor feedback obtained from the battery pack.
[0005] Another limitation of current charging technologies is the absence of integrated mechanisms for real-time impedance estimation, adaptive current modulation, and noise-resistant sensing. Accurate measurement of battery parameters is essential for precise charging control, particularly in high-current applications such as electric vehicles. However, electrical interference and measurement noise can degrade the reliability of sensor data, thereby affecting the effectiveness of adaptive charging algorithms. Additionally, most existing systems do not incorporate isolation-based sensing techniques to ensure accurate signal acquisition under high-power operating conditions.
[0006] The present invention solves the limitations of the prior art by providing a Pulse-Synchronized (PS) adaptive charging system that dynamically regulates charging parameters such as current amplitude, pulse duration, and mode transition thresholds based on real-time measurements of battery voltage, temperature, and state of charge.
[0007] Thus, in light of the above-stated discussion, there exists a need for a Pulse-Synchronized (PS) charging system for lithium-ion batteries.
SUMMARY OF THE DISCLOSURE
[0008] The following is a summary description of illustrative embodiments of the invention. It is provided as a preface to assist those skilled in the art to more rapidly assimilate the detailed design discussion which ensues and is not intended in any way to limit the scope of the claims which are appended hereto in order to particularly point out the invention.
[0009] According to illustrative embodiments, the present disclosure focuses on a Pulse-Synchronized (PS) charging system for lithium-ion batteries which overcomes the above-mentioned disadvantages or provides the users with a useful or commercial choice.
[0010] An objective of the present disclosure is to provide an adaptive hybrid charging system that integrates constant-current (CC), pulse-based charging, and constant-voltage (CV) modes within a unified charging framework.
[0011] Another objective of the present disclosure is to dynamically regulate charging parameters such as charging current, pulse amplitude, pulse duration, and pulse interval based on real-time battery measurements including voltage, current, temperature, and state-of-charge (SoC).
[0012] Another objective of the present disclosure is to enhance ion mobility and reduce electrochemical polarization during intermediate charging stages through dynamically controlled pulse charging.
[0013] Another objective of the present disclosure is to achieve higher charge efficiency, and exhibits good thermal uniformity compared to conventional CC CV.
[0014] Another objective of the present disclosure is maintain uniform thermal distribution across the battery pack by monitoring temperature and adjusting charging current to prevent overheating and thermal hotspots.
[0015] Another objective of the present disclosure is to improve overall charging efficiency and reduce charging time compared to conventional constant-current constant-voltage charging methods.
[0016] Yet another objective of the present disclosure is to minimize battery degradation and extend cycle life by avoiding excessive current stress and maintaining safe operating conditions during charging.
[0017] In light of the above, in one aspect of the present disclosure, a Pulse-Synchronized (PS) charging system for lithium-ion batteries is disclosed herein. The system comprises a battery pack, comprising a plurality of lithium-ion cells electrically connected in series, parallel, or a combination thereof, the battery pack configured to store electrical energy and supply power. The system includes a charge control unit connected to the system, the charge control unit configured to regulate electrical power supplied to the battery pack and to operate in multiple charging modes. The system also includes a plurality of sensors integrated with the battery pack, configured to continuously measure operating parameters of the battery pack and generate corresponding sensor signals. The system also includes a processing unit operatively connected to the plurality of sensors and the charge control unit, the processing unit configured to dynamically adjust charging parameters based on real-time battery condition data. The processing unit comprises an input module configured to receive measurement signals from the plurality of sensors associated with the battery pack, a data processing module configured to filter, condition, and convert the received measurement signals into processed battery condition data suitable for further analysis, a charge state estimation module configured to determine a real-time state-of-charge (SoC) of the battery pack based on the processed voltage and current data and to generate a charge state output representative of the energy level of the battery pack, an impedance estimation module configured to estimate an internal resistance of the battery pack using variations in measured voltage and current characteristics during charging operations, a charging mode selection module configured to determine an appropriate charging mode from a plurality of charging modes based on the charge state output and the estimated internal resistance, a mode transition control module configured to determine switching points between the constant-current mode, the pulse-based charging mode, and the constant-voltage mode based on at least one of a voltage gradient, a state-of-charge slope, and charging current characteristics, an adaptive pulse control module configured to generate and dynamically adjust pulse charging parameters including pulse amplitude, pulse duration, and pulse interval in response to the real-time battery condition data, an output module configured to generate control signals and transmit the control signals to the charge control unit for regulating current and voltage supplied to the battery pack, and a user interface integrated with a user device, configured to display battery charging parameters including voltage, current, temperature, and state-of-charge (SoC), and to enable monitoring and control of the charging process.
[0018] In one embodiment, a cloud database is provided for storing historical battery charging data, operational parameters, and performance metrics.
[0019] In one embodiment, the multiple charging modes including a constant-current (CC) charging mode, a pulse-based charging mode, and a constant-voltage (CV) charging mode.
[0020] In one embodiment, the system includes a power source, configured to provide electrical energy for charging a battery pack, the power source comprising at least one AC or DC supply unit adapted to deliver regulated electrical power to a charging circuit.
[0021] In one embodiment, the plurality of sensors includes a voltage sensor, a current sensor, and a temperature sensor.
[0022] In one embodiment, the system includes an isolation circuitry linked to the sensors and processing unit, configured to separate the high-power battery charging circuit from the low-power control electronics to protect the system and ensure that measurements are accurate and noise-free.
[0023] In one embodiment, the system includes a thermal management module is configured to monitor temperature data from the temperature sensor and to limit charging current, modify pulse parameters, or initiate a cooling mechanism when the temperature exceeds a predefined safety threshold.
[0024] In one embodiment, the system includes a feedback module is configured to receive real-time measurements of battery parameters including voltage, current, temperature, and state of charge, and to dynamically adjust charging parameters including current level, pulse amplitude, pulse duration, and charging mode transition points based on the received measurements.
[0025] In one embodiment, the adaptive pulse control module calculates voltage gradient changes across charging intervals using a Pulse-Synchronized (PS) algorithm to determine optimal switching from pulse-controlled mode to constant-voltage mode.
[0026] In light of the above, in one aspect of the present disclosure, a Pulse-Synchronized (PS) charging system for lithium-ion batteries is disclosed herein. The method includes supplying electrical power to a battery pack through a charge control unit configured to operate in multiple charging modes. The method also includes sensing operating parameters of the battery pack using a plurality of sensors, the operating parameters including at least voltage, current, temperature, and battery operating characteristics, and generating corresponding sensor signals. The method also includes receiving the sensor signals at a processing unit and processing the received sensor signals to obtain conditioned battery condition data. The method also includes determining a real-time state-of-charge (SoC) of the battery pack based on processed voltage and current data by a charge state estimation module. The method also includes estimating an internal resistance of the battery pack based on variations in measured voltage and current characteristics during charging by an impedance estimation module. The method also includes selecting an appropriate charging mode from a plurality of charging modes including constant-current mode, pulse-based charging mode, and constant-voltage mode, based on the determined state-of-charge and estimated internal resistance by a charging mode selection module. The method also includes determining switching points between the constant-current mode, the pulse-based charging mode, and the constant-voltage mode based on at least one of a voltage gradient, state-of-charge slope, and charging current characteristics by a mode transition control module. The method also includes adjusting pulse charging parameters including pulse amplitude, pulse duration, and pulse interval based on real-time battery condition data by an adaptive pulse control module. The method also includes generating control signals corresponding to the selected charging mode and pulse charging parameters and transmitting the control signals to the charge control unit to regulate current and voltage supplied to the battery pack. The method also includes displaying battery charging parameters including voltage, current, temperature, and state-of-charge on a user interface integrated with a user device to enable monitoring and control of the charging process.
[0027] These and other advantages will be apparent from the present application of the embodiments described herein.
[0028] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
[0029] These elements, together with the other aspects of the present disclosure and various features are pointed out with particularity in the claims annexed hereto and form a part of the present disclosure. For a better understanding of the present disclosure, its operating advantages, and the specified object attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] To describe the technical solutions in the embodiments of the present disclosure or in the prior art more clearly, the following briefly describes the accompanying drawings required for describing the embodiments or the prior art. Apparently, the accompanying drawings in the following description merely show some embodiments of the present disclosure, and a person of ordinary skill in the art can derive other implementations from these accompanying drawings without creative efforts. All of the embodiments or the implementations shall fall within the protection scope of the present disclosure.
[0031] The advantages and features of the present disclosure will become better understood with reference to the following detailed description taken in conjunction with the accompanying drawing, in which:
[0032] FIG. 1 illustrates a block diagram of a Pulse-Synchronized (PS) charging system for lithium-ion batteries, in accordance with an exemplary embodiment of the present disclosure; and
[0033] FIG. 2 illustrates a method for charging a lithium-ion battery, in accordance with an exemplary embodiment of the present disclosure.
[0034] Like reference, numerals refer to like parts throughout the description of several views of the drawing.
[0035] The Pulse-Synchronized (PS) charging system for lithium-ion batteries is illustrated in the accompanying drawings, which like reference letters indicate corresponding parts in the various figures. It should be noted that the accompanying figure is intended to present illustrations of exemplary embodiments of the present disclosure. This figure is not intended to limit the scope of the present disclosure. It should also be noted that the accompanying figure is not necessarily drawn to scale.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0036] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.
[0037] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the present disclosure. It may be apparent to one skilled in the art that embodiments of the present disclosure may be practiced without some of these specific details.
[0038] Various terms as used herein are shown below. To the extent a term is used, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0039] The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
[0040] The terms “having”, “comprising”, “including”, and variations thereof signify the presence of a component.
[0041] Referring now to FIG. 1 and FIG. 2 to describe various exemplary embodiments of the present disclosure. FIG. 1 illustrates a block diagram of a Pulse-Synchronized (PS) charging system 100 for lithium-ion batteries, in accordance with an exemplary embodiment of the present disclosure.
[0042] The system 100 includes a battery pack 102, comprising a plurality of lithium-ion cells electrically connected in series, parallel, or a combination thereof, the battery pack 102 configured to store electrical energy and supply power.
[0043] A charge control unit 104 is connected to the system 100, the charge control unit 104 configured to regulate electrical power supplied to the battery pack 102 and to operate in multiple charging modes.
[0044] In one embodiment of the present invention, multiple charging modes includes a constant-current (CC) charging mode, a pulse-based charging mode, and a constant-voltage (CV) charging mode. The constant-current charging mode is configured to deliver a predetermined charging current to the battery pack 102 during an initial stage of charging until a predefined voltage threshold or state-of-charge level is reached. The pulse-based charging mode is configured to apply controlled current pulses with variable amplitude and timing to the battery pack 102 during an intermediate charging stage in order to enhance lithium-ion mobility within the electrochemical cells, reduce polarization effects, and improve charge acceptance characteristics of the battery.
[0045] A plurality of sensors 106 are integrated with the battery pack 102, configured to continuously measure operating parameters of the battery pack 102 and generate corresponding sensor signals.
[0046] In one embodiment of the present invention, the plurality of sensors 106 includes a voltage sensor, a current sensor, and a temperature sensor.
[0047] The voltage sensor is configured to measure the terminal voltage of the battery pack 102 or individual cells and generate a voltage signal corresponding to the measured value.
[0048] The current sensor is configured to measure the charging current supplied to the battery pack 102 and generate a current signal indicative of the magnitude and direction of the current flow.
[0049] The temperature sensor is positioned in thermal contact with the battery pack 102 and is configured to measure the operating temperature of the cells during charging.
[0050] The voltage signal, current signal, and temperature signal are provided to the charge control unit 104, which processes the signals to estimate parameters including state-of-charge (SoC), voltage gradient, and internal impedance of the battery pack 102. Based on these parameters, the charge control unit 104 dynamically adjusts the charging current, pulse amplitude, pulse duration, and mode transition points in accordance with the pulse-synchronized charging algorithm, thereby ensuring efficient, safe, and adaptive charging operation.
[0051] A communication network 108 is connected to the processing unit 110, the plurality of sensors 106, the charge control unit 104, and the user interface 130, the communication network 108 being configured to transmit data between the several components of the system 100.
[0052] In one embodiment of the present invention, the communication network 108 may be both wired and wireless.
[0053] In one embodiment of the present invention, the communication network 108 may include, Wi-Fi, Bluetooth, Ethernet, cellular networks such as 2G, 3G, 4G, and 5G, Wide Area Network (WAN), Local Area Network (LAN), and Virtual Area Network (VAN), serial communication protocols, and universal serial bus (USB) interfaces for an input/output connectivity.
[0054] In one embodiment of the present invention, the communication network 108 may include an antenna supporting long-range wireless communication.
[0055] In one embodiment of the present invention, a cloud database 128 is provided for storing historical battery charging data, operational parameters, and performance metrics.
[0056] In one embodiment of the present invention, the system 100 includes a power source 138 that is configured to provide electrical energy for charging a battery pack 102, the power source 138 comprising at least one AC or DC supply unit adapted to deliver regulated electrical power to a charging circuit.
[0057] A processing unit 110 is operatively connected to the plurality of sensors 106 and the charge control unit 104, the processing unit 110 configured to dynamically adjust charging parameters based on real-time battery condition data. The processing unit 110 receives measurement signals from the sensors, processes the signals to determine the operating condition of the battery pack 102, and generates control signals that regulate the charging process. Through its integrated modules, the processing unit 110 continuously analyzes battery parameters and dynamically adapts charging modes and pulse characteristics to ensure efficient, safe, and optimized charging of the battery pack 102.
[0058] The processing unit 110 includes several modules:
[0059] An input module 112 is configured to receive measurement signals from the plurality of sensors 106 associated with the battery pack 102. These measurement signals correspond to parameters such as battery voltage, charging current, and cell temperature. The input module 112 serves as an interface between the sensor circuitry and the processing unit 110, enabling reliable acquisition of real-time sensor data.
[0060] In one embodiment of the present invention, the input module 112 may include analog input channels, signal acquisition circuits, and analog-to-digital conversion components that convert analog sensor signals into digital signals suitable for processing by the processing unit 110.
[0061] A data processing module 114 is configured to filter, condition, and convert the received measurement signals into processed battery condition data suitable for further analysis. The data processing module 114 may also perform digital filtering and calibration to remove measurement errors caused by electrical noise, sensor drift, or environmental interference. The resulting processed data is then forwarded to subsequent modules for advanced analysis and control decisions.
[0062] A charge state estimation module 116 is configured to determine a real-time state-of-charge (SoC) of the battery pack 102 based on the processed voltage and current data and to generate a charge state output representative of the energy level of the battery pack 102. The SoC represents the available energy in the battery pack 102 relative to its total capacity. The charge state estimation module 116 calculates the SoC using computational techniques such as coulomb counting, voltage-based estimation, or hybrid estimation methods. The estimated SoC is generated as a charge state output that represents the energy level of the battery pack 102 at a given time. This charge state output is subsequently used by other modules to determine appropriate charging strategies and transition points between charging modes.
[0063] An impedance estimation module 118 is configured to estimate an internal resistance of the battery pack 102 using variations in measured voltage and current characteristics during charging operations.
[0064] In one embodiment of the present invention, the impedance estimation module 118 determines the internal resistance by analyzing the relationship between changes in current and the corresponding voltage response during charging or pulse events. The estimated internal resistance provides valuable information that enables the system 100 to adjust charging parameters to reduce losses, improve efficiency, and minimize battery degradation.
[0065] A charging mode selection module 120 is configured to determine an appropriate charging mode from a plurality of charging modes based on the charge state output and the estimated internal resistance.
[0066] In one embodiment of the present invention, the available charging modes may include a constant-current (CC) mode, a pulse-based charging mode, and a constant-voltage (CV) mode. The module evaluates the battery condition data and selects the most suitable charging mode that optimizes charging speed while maintaining safe operating limits. For example, the CC mode may be selected when the battery pack 102 is at a low SoC, while the pulse-based charging mode may be activated during intermediate charging stages to enhance electrochemical reactions and reduce polarization effects.
[0067] In one embodiment of the present invention, the constant-voltage charging mode is activated when the battery pack 102 approaches a near-full state-of-charge condition, wherein the charge control unit 104 maintains a substantially constant voltage across the battery pack 102 while gradually reducing the charging current until a predefined termination condition is satisfied. The transition between the constant-current mode, the pulse-based charging mode, and the constant-voltage mode is dynamically determined by the pulse-synchronized (PS) algorithm based on real-time analysis of sensed parameters including voltage gradients, state-of-charge slope, temperature variation, and estimated internal impedance of the battery pack 102.
[0068] A mode transition control module 122 is configured to determine switching points between the constant-current mode, the pulse-based charging mode, and the constant-voltage mode based on at least one of a voltage gradient, a state-of-charge slope, and charging current characteristics. This dynamic transition mechanism ensures that the battery pack 102 is charged efficiently without causing excessive heat generation or electrochemical stress on the cells.
[0069] An adaptive pulse control module 124 is configured to generate and dynamically adjust pulse charging parameters including pulse amplitude, pulse duration, and pulse interval in response to the real-time battery condition data.
[0070] In one embodiment of the present invention, the adaptive pulse control module 124 calculates voltage gradient changes across charging intervals using a Pulse-Synchronized (PS) algorithm to determine optimal switching from pulse-controlled mode to constant-voltage mode. The adaptive pulse control module 124 enables the system 100 to implement adaptive pulse charging during intermediate stages of the charging process. By adjusting pulse characteristics according to battery conditions, the module improves lithium-ion diffusion within the electrode materials, reduces polarization effects, and lowers internal resistance buildup. The adaptive nature of the pulse control module 124 allows the charging system 100 to maintain optimal charging performance under varying battery conditions.
[0071] An output module 126 is configured to generate control signals and transmit the control signals to the charge control unit 104 for regulating current and voltage supplied to the battery pack 102. These control signals are transmitted to the charge control unit 104, which regulates the current and voltage supplied to the battery pack 102 accordingly. The output module 126 may include digital control interfaces, pulse-width modulation (PWM) generators, or other control circuitry capable of driving power electronic components within the charging circuit.
[0072] A user interface 130 is linked with the output module 126, configured to display battery charging parameters including voltage, current, temperature, and state-of-charge (SoC), and to enable monitoring and control of the charging process. The user interface 130 enables a user or system 100 operator to monitor the charging process in real time and observe the operational status of the battery pack 102.
[0073] In one embodiment of the present invention, the system 100 includes an isolation circuitry 132 linked to the sensors and processing unit 110, configured to separate the high-power battery charging circuit from the low-power control electronics to protect the system 100 and ensure that measurements are accurate and noise-free.
[0074] In one embodiment of the present invention, the system 100 includes a thermal management module 134 is configured to monitor temperature data from the temperature sensor and to limit charging current, modify pulse parameters, or initiate a cooling mechanism when the temperature exceeds a predefined safety threshold.
[0075] In one embodiment of the present invention, the system 100 includes a feedback module 136 is configured to receive real-time measurements of battery parameters including voltage, current, temperature, and state of charge, and to dynamically adjust charging parameters including current level, pulse amplitude, pulse duration, and charging mode transition points based on the received measurements.
[0076] In one exemplary embodiment of the present invention, the adaptive battery charging system 100 was experimentally implemented to validate the operation of the pulse-synchronized (PS) charging algorithm. The system 100 was built using a microcontroller-based processing unit 110 configured to execute the adaptive charging control logic in real time. The processing unit 110 was interfaced with a plurality of sensors 106 including a voltage sensor, a current sensor, and a temperature sensor configured to continuously monitor the operating parameters of the battery pack 102 during charging. The experimental battery pack 102 comprised eight lithium-ion cells based on nickel-manganese-cobalt (NMC) chemistry having a nominal capacity of approximately 6000 mAh. The cells were electrically connected to form a battery pack 102 suitable for evaluating the charging performance under controlled conditions. Sensor measurements were transmitted to the processing unit 110, which analyzed the data to determine state-of-charge (SoC), estimate internal resistance, and dynamically adjust charging parameters. During operation, the system 100 initially applied a constant-current charging mode, followed by an adaptive pulse-based charging mode at intermediate SoC levels to enhance ion mobility and reduce polarization effects. As the battery approached full charge, the system 100 transitioned to a constant-voltage mode until the charging termination condition was reached. Experimental results demonstrated reduced charging time, improved charge efficiency, and stable thermal behavior compared to conventional charging methods.
[0077] FIG. 2 illustrates a method 200 for charging a lithium-ion battery, in accordance with an exemplary embodiment of the present disclosure.
[0078] The method 200 may include the following steps:
[0079] At 202, supplying electrical power to a battery pack 102 through a charge control unit 104 configured to operate in multiple charging modes. The electrical power from the power source 138 is supplied to the battery pack 102 through the charge control unit 104 configured to regulate the magnitude and timing of the charging current and voltage.
[0080] At 204, sensing operating parameters of the battery pack 102 using a plurality of sensors 106, the operating parameters including at least voltage, current, temperature, and battery operating characteristics, and generating corresponding sensor signals. The continuous acquisition of these parameters enables the charging system 100 to track the operational state of the battery and to detect variations in electrical or thermal behavior during charging.
[0081] At 206, receiving the sensor signals at a processing unit 110 and processing the received sensor signals to obtain conditioned battery condition data. The processing unit 110 performs signal conditioning and data processing operations, such as filtering, analog-to-digital conversion, and noise reduction, to obtain reliable and conditioned battery condition data. This processed data forms the basis for subsequent control decisions related to charging mode selection and parameter adjustment.
[0082] At 208, determining a real-time state-of-charge (SoC) of the battery pack 102 based on processed voltage and current data by a charge state estimation module 116. The SoC represents the remaining charge capacity of the battery relative to its total capacity. The estimation module may use computational techniques such as coulomb counting, voltage-based estimation, or hybrid estimation methods to calculate the SoC. The determined SoC provides a key indicator of the charging stage and is used by the control system 100 to determine appropriate charging strategies.
[0083] At 210, estimating an internal resistance of the battery pack 102 based on variations in measured voltage and current characteristics during charging by an impedance estimation module 118. The internal resistance may be determined by observing transient voltage responses corresponding to changes in charging current or pulse events. The estimated internal resistance provides information about the electrochemical condition of the battery cells and may indicate factors such as polarization effects, aging, or degradation. This information is used to improve charging efficiency and safety.
[0084] At 212, selecting an appropriate charging mode from a plurality of charging modes including constant-current (CC) mode, pulse-based charging mode, and constant-voltage (CV) mode, based on the determined state-of-charge and estimated internal resistance by a charging mode selection module 120. The selection process is based on the determined state-of-charge and the estimated internal resistance of the battery pack 102. For example, the CC mode may be selected during the initial charging stage when the battery has a low SoC, the pulse-based mode may be selected during intermediate charging stages to improve ion mobility and reduce polarization, and the CV mode may be applied when the battery approaches full charge.
[0085] At 214, determining switching points between the constant-current mode, the pulse-based charging mode, and the constant-voltage mode based on at least one of a voltage gradient, state-of-charge slope, and charging current characteristics by a mode transition control module 122.
[0086] At 216, adjusting pulse charging parameters including pulse amplitude, pulse duration, and pulse interval based on real-time battery condition data by an adaptive pulse control module 124. The adjustment is performed based on real-time battery condition data obtained from the sensors and processed by the processing unit 110. By modifying the pulse characteristics in response to changing battery conditions, the system 100 improves lithium-ion diffusion within the battery cells, reduces internal resistance buildup, and minimizes thermal stress during the charging process.
[0087] At 218, generating control signals corresponding to the selected charging mode and pulse charging parameters and transmitting the control signals to the charge control unit 104 to regulate current and voltage supplied to the battery pack 102. These control signals are transmitted to the charge control unit 104, which regulates the current and voltage supplied to the battery pack 102 accordingly. The charge control unit 104 adjusts its switching circuitry and power regulation elements in response to the control signals, thereby implementing the desired charging profile in real time.
[0088] At 220, displaying battery charging parameters including voltage, current, temperature, and state-of-charge on a user interface 130 linked with the output module 126 to enable monitoring and control of the charging process. The displayed parameters may include battery pack 102 voltage, charging current, cell temperature, estimated state-of-charge (SoC), charging mode status, and other diagnostic indicators associated with the battery condition. The output module 126 continuously receives processed battery condition data from the processing unit 110 and converts the data into user-readable information. The interface may present the parameters in the form of numerical values, graphical plots, progress indicators, or status notifications that illustrate the real-time charging state of the battery pack 102.
[0089] In the best mode of operation, the Pulse-Synchronized (PS) charging system 100 for lithium-ion batteries starts using a microcontroller-based processing unit 110 integrated with sensing circuitry, a charge control unit 104, and a lithium-ion battery pack 102. The battery pack 102 comprises a plurality of lithium-ion cells, preferably nickel-manganese-cobalt (NMC) chemistry cells, electrically connected in series or series-parallel configuration to provide the required voltage and capacity. The charge control unit 104 is connected between an external regulated power source 138 and the battery pack 102 and is configured to deliver controlled electrical power under different charging modes including constant-current (CC), pulse-based charging, and constant-voltage (CV) modes. In operation, the plurality of sensors 106 continuously measure battery parameters including voltage, charging current, and temperature. The sensor signals are transmitted through the communication network 108 to the processing unit 110 where they are filtered and processed to obtain accurate battery condition data.
[0090] The processing unit 110 determines the real-time state-of-charge (SoC) using processed voltage and current data and estimates internal resistance of the battery pack 102 based on voltage–current variations observed during charging. Initially, the system 100 operates in constant-current mode to rapidly charge the battery at a controlled current level. When the SoC reaches an intermediate level, the system 100 transitions to pulse-based charging mode in which adaptive current pulses are applied to enhance ion mobility, reduce polarization effects, and limit thermal build-up. The amplitude, duration, and interval of the pulses are dynamically adjusted based on real-time battery condition data. As the battery approaches full charge, the system 100 transitions to constant-voltage mode where the charging voltage is maintained at a predetermined level while the charging current gradually decreases until a termination threshold is reached.
[0091] While the invention has been described in connection with what is presently considered to be the most practical and various embodiments, it will be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
[0092] A person of ordinary skill in the art may be aware that, in combination with the examples described in the embodiments disclosed in this specification, units and algorithm steps may be implemented by electronic hardware, computer software, or a combination thereof.
[0093] The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described to best explain the principles of the present disclosure and its practical application, and to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the present disclosure.
[0094] Disjunctive language such as the phrase “at least one of X, Y, Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and/or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain embodiments require at least one of X, at least one of Y, or at least one of Z to each be present.
[0095] In a case that no conflict occurs, the embodiments in the present disclosure and the features in the embodiments may be mutually combined. The foregoing descriptions are merely specific implementations of the present disclosure, but are not intended to limit the protection scope of the present disclosure. Any variation or replacement readily figured out by a person skilled in the art within the technical scope disclosed in the present disclosure shall fall within the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure shall be subject to the protection scope of the claims.
, Claims:I/We Claim:
1. A Pulse-Synchronized (PS) charging system (100) for lithium-ion batteries, the system (100) comprising:
a battery pack (102), comprising a plurality of lithium-ion cells electrically connected in series, parallel, or a combination thereof, the battery pack (102) configured to store electrical energy and supply power;
a charge control unit (104) connected to the system (100), the charge control unit (104) configured to regulate electrical power supplied to the battery pack (102) and to operate in multiple charging modes;
a plurality of sensors (106) integrated with the battery pack (102), configured to continuously measure operating parameters of the battery pack (102) and generate corresponding sensor signals;
a communication network (108) provided with the system (100), the communication network (108) being configured to transmit data between the several components of the system (100);
a processing unit (110) operatively connected to the plurality of sensors (106) and the charge control unit (104), the processing unit (110) configured to dynamically adjust charging parameters based on real-time battery condition data, the processing unit (110) comprising:
an input module (112) configured to receive measurement signals from the plurality of sensors (106) associated with the battery pack (102);
a data processing module (114) configured to filter, condition, and convert the received measurement signals into processed battery condition data suitable for further analysis;
a charge state estimation module (116) configured to determine a real-time state-of-charge (SoC) of the battery pack (102) based on the processed voltage and current data and to generate a charge state output representative of the energy level of the battery pack (102);
an impedance estimation module (118) configured to estimate an internal resistance of the battery pack (102) using variations in measured voltage and current characteristics during charging operations;
a charging mode selection module (120) configured to determine an appropriate charging mode from a plurality of charging modes based on the charge state output and the estimated internal resistance;
a mode transition control module (122) configured to determine switching points between the constant-current mode, the pulse-based charging mode, and the constant-voltage mode based on at least one of a voltage gradient, a state-of-charge slope, and charging current characteristics;
an adaptive pulse control module (124) configured to generate and dynamically adjust pulse charging parameters including pulse amplitude, pulse duration, and pulse interval in response to the real-time battery condition data;
an output module (126) configured to generate control signals and transmit the control signals to the charge control unit (104) for regulating current and voltage supplied to the battery pack (102); and
an user interface (130) linked with the output module (126), configured to display battery charging parameters including voltage, current, temperature, and state-of-charge (SoC), and to enable monitoring and control of the charging process.
2. The system (100) as claimed in claim 1, wherein a cloud database (128) is provided for storing historical battery charging data, operational parameters, and performance metrics.
3. The system (100) as claimed in claim 1, wherein the multiple charging modes including a constant-current (CC) charging mode, a pulse-based charging mode, and a constant-voltage (CV) charging mode.
4. The system (100) as claimed in claim 1, wherein the system (100) includes a power source (138), configured to provide electrical energy for charging a battery pack (102), the power source (138) comprising at least one AC or DC supply unit adapted to deliver regulated electrical power to a charging circuit.
5. The system (100) as claimed in claim 1, wherein the plurality of sensors (106) includes a voltage sensor, a current sensor, and a temperature sensor.
6. The system (100) as claimed in claim 1, the system (100) includes an isolation circuitry (132) linked to the sensors and processing unit (110), configured to separate the high-power battery charging circuit from the low-power control electronics to protect the system (100) and ensure that measurements are accurate and noise-free.
7. The system (100) as claimed in claim 1, wherein the system (100) includes a thermal management module (134) is configured to monitor temperature data from the temperature sensor and to limit charging current, modify pulse parameters, or initiate a cooling mechanism when the temperature exceeds a predefined safety threshold.
8. The system (100) as claimed in claim 1, the system (100) includes a feedback module (136) is configured to receive real-time measurements of battery parameters including voltage, current, temperature, and state of charge, and to dynamically adjust charging parameters including current level, pulse amplitude, pulse duration, and charging mode transition points based on the received measurements.
9. The system (100) as claimed in claim 1, wherein the adaptive pulse control module (124) calculates voltage gradient changes across charging intervals using a Pulse-Synchronized (PS) algorithm to determine optimal switching from pulse-controlled mode to constant-voltage mode.
10. A method (200) for charging a lithium-ion battery, the method comprising:
supplying electrical power to a battery pack (102) through a charge control unit (104) configured to operate in multiple charging modes;
sensing operating parameters of the battery pack (102) using a plurality of sensors (106), the operating parameters including at least voltage, current, temperature, and battery operating characteristics, and generating corresponding sensor signals;
receiving the sensor signals at a processing unit (110) and processing the received sensor signals to obtain conditioned battery condition data;
determining a real-time state-of-charge (SoC) of the battery pack (102) based on processed voltage and current data by a charge state estimation module (116);
estimating an internal resistance of the battery pack (102) based on variations in measured voltage and current characteristics during charging by an impedance estimation module (118);
selecting an appropriate charging mode from a plurality of charging modes including constant-current mode, pulse-based charging mode, and constant-voltage mode, based on the determined state-of-charge and estimated internal resistance by a charging mode selection module (120);
determining switching points between the constant-current mode, the pulse-based charging mode, and the constant-voltage mode based on at least one of a voltage gradient, state-of-charge slope, and charging current characteristics by a mode transition control module (122);
adjusting pulse charging parameters including pulse amplitude, pulse duration, and pulse interval based on real-time battery condition data by an adaptive pulse control module (124);
generating control signals corresponding to the selected charging mode and pulse charging parameters and transmitting the control signals to the charge control unit (104) to regulate current and voltage supplied to the battery pack (102); and
displaying battery charging parameters including voltage, current, temperature, and state-of-charge on a user interface (130) linked with the output module (126) to enable monitoring and control of the charging process.