Description:[0040] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.
[0041] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures, or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similarlanguage throughout this specification may, but not necessarily do, all refer to the same embodiment.
[0042] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
[0043] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
[0044] Embodiments of the present invention disclose an integrated inverter system (100).
[0045] Fig. 1 illustrates a block diagram of the integrated inverter system in accordance with an embodiment of the present invention. According to an embodiment of the present invention, theintegrated inverter system (100), comprises a battery pack (102) comprising a plurality of lithium-ion batteries. Abattery management sub-system (BMS) (104) configured to monitor and regulate the battery pack (102) in real time. An inverter circuit (106) configured to convert direct current (DC) from the battery pack (102) by a transformer (108) into alternating current (AC) exhibiting a pure sine wave output with a minimal harmonic distortion. A cooling sub-system (110) configuredto dissipate heat generated by the battery pack (102), the inverter circuit (106), and the transformer (108). A user interface (112) comprises a display (112a) and an On/Off switch (112b), wherein the display (112a) is configured to provide real-time information on a plurality of parameters of the inverter system (100) and a charging circuit (114) with Constant Current Constant Voltage (CCCV) charging mechanism is configured to charge the battery pack (104), maintaining its nominal operating conditions.
[0046] According to an embodiment of the present invention, wherein the BMS (104) comprisesa passive balancing module in each of the lithium-ion battery cellsand is configured toprevent overcharging and over-discharging and balances the individual lithium-ion battery cell during the charging and discharging operations.
[0047] According to an embodiment of the present invention,wherein the inverter circuit (106) providesa regulated sinusoidal output voltage and a high input power factor irrespective of voltage fluctuations.
[0048] According to an embodiment of the present invention, integration of lithium-ion batteries with the inverter circuit (106) enables significant reduction in weight, prolongs the system's life cycle, and enhances overall efficiency.
[0049] According to an embodiment of the present invention, wherein the cooling sub-system (110) comprises a DC fan positioned on a back panel (6) of the inverter box (300) and opposite to a heat sink, to exhaust hot air outside for efficient performance and safety controls.It can be noted that maintaining the inverter system (100) at optimal operating temperatures and increases overall system efficiency. Further, the BMS (104) and cooling sub-system (110) work in tandem to ensure optimal battery health, temperature regulation, and efficient energy transfer during charge and discharge cycles
[0050] According to an embodiment of the present invention, wherein the inverter box (300) further includes a top cover (7) with dimensions designed to accommodate the assembled components and facilitate ease of assembly and disassembly.
[0051] According to an embodiment of the present invention, wherein the inverter box (300) includes a front panel (2) with the LCD display (2A), On/Off switch (2B), and other indicators, a bottom panel (1) for placing the battery pack (102), MCB, and 3-pin socket for protection and charging.
[0052] According to an embodiment of the present invention, wherein the inverter circuit (106) comprises super enamel copper round wires or rectangular strips of insulation class "F" or "H" for the transformers (108).
[0053] According to an embodiment of the present invention, further comprising a fuse/MCB switch (6D) for circuit protection and safety.
[0054] Fig. 2 illustrates a block diagram of an inverter circuit (106) block diagram of the inverter system in accordance with an embodiment of the present invention.According to an embodiment of the present invention, an inverter circuit (106) for the inverter system is disclosed. The inverter circuit (106) comprises an AC mains supply (202) serving as a primary power source, the AC mains supply (202) comprises a power flow bifurcation. A charger component (204) in communication with the AC mains supply (202), the charger component adapted to receive a portion of power from the AC mains supply (202) and direct the portion of power for charging. An AC to AC step down converter (204a) with Constant Current Constant Voltage (CCCV) charging feature integrated within the charger component (204), the AC to AC Step Down Converter (204a) adapted to convert incoming AC power to a lower voltage suitable for charging a lithium-ion battery pack (102), the CCCV Charging feature controlling the charging process of the lithium-ion battery pack (102). The lithium-ion battery pack battery pack (102) is integrated with a battery management system (BMS) (102), the LIB battery pack (102) adapted to receive power from the AC to AC Step Down Converter (204a) and being integrated with the BMS (104), the BMS (102) being configured to monitor and manage the charging process of the lithium-ion battery pack (102).
[0055] According to an embodiment of the present invention, a DC to AC Step Up Converter (206) component in communication with the lithium-ion battery pack (102), the DC to AC Step Up Converter (206) adapted to convert DC energy from the lithium-ion battery pack (102) into a higher AC voltage suitable for powering loads. A filter section (208) in communication with the DC to AC Step Up Converter (206), the filter Section (208) is adapted to receive the AC output from the DC to AC Step Up Converter (206) and remove harmonics and noise from the AC output, resulting in a clean sine wave output. A switching circuit (210) in communication with the filter section (208) is configured to regulate or control the AC power received from the filter section (208) and delivers AC power to one or more loads, wherein the loads comprise household or electronic devices.
[0056] According to an embodiment of the present invention, the inverter circuit (106) is configured to maintain a continuous supply of AC power to desired loads during power failures or off-grid operation.
[0057] Table: 1 comprises various non-limiting dimensions for a different variantsof the inverter system (100)with its corresponding parts and reference numeralsillustrated Figure no 3, 4 and 5are tabulated herein below.
Part No. Sub-Part No. Part and Sub-Part Description
All the dimension are in mm Part Physical Dimension
250 VA 500 VA 850 VA 1000 VA 1500 VA 2000 VA
Inverter Box (L x W x H) 310x190x180 316x190x215 361x367x262 361x380 x297 361x400x350 361x400x350
1 Bottom (L x W) 310x190 316x190 361x367 361x380 361x400 361x400
1A Transformer: Position (L x W) 115 x 75 115 x 100 116 x 115 140 x 115 140*153 165x153
Transformer: Vent (L x W) 17 x 6 14x7.5 17 x 6 17 x 6 17 x 9 17 x 9
1B Battery: Position with vent (L x W) 19 x 7 19x7 30 x 10 30 x 10 30 x 10 30 x 10
Vent inter-distance/ No. of rows 21/5row 21/5row 20/10row 20/10row 20/10row 20/10row
2 Front(L x H) 190x180 190x215 362x362 361x297 400x350 400x350
2A LCD display (L x W) 65 x 14 65 x 14 65 x 14 65 x 14 65 x 14 65 x 14
2B On/Off switch (Diameter) 12 12 12 12 12 12
3 PCB stand (L x H x W) 167x60x120 167x110x120 132x150x185 132x150x185 132x150x185 132x150x185
4 Right Side (W x H) 310 x 180 316 x 215 361x262 361x297 361x350 361x350
4A Vent dimension (W x H) 228x54 228x54 302x90 301x100 301x100 301x100
4B No. of vent rows/columns 2x29 2x29 13x43 14x43 14x43 14x43
4C Inter-row distance 6 6 1 1 1 1
4D Vent diameter/dimension 24 x 4 24 x 4 5 5 5 5
5 Left Side (L x H) 310 x 180 316 x 215 361x262 361x297 361x350 361x350
5A Vent dimension (W x H) 228 x 54 228 x 54 302x90 301x100 301x100 301x100
5B No. of vent rows/columns 2 x 29 2 x 29 13x43 14x43 14x43 14x43
5C Inter-row distance 6 6 1 1 1 1
5D Vent diameter/dimension 24 x 4 24 x 4 5 5 5 5
6 Rear (L x H) 190x180 190x215 362x362 361x297 400x350 400x350
6A Radial exhaust vent (Max./Min.) 90 (max.)
5 (min.) 90 (max.)
5 (min.) 92.5 (max.)
5 (min.) 92.5 (max.)
5 (min.) 92.5 (max.) 92.5 (max.)
Vent radial separation Nonmetric Nonmetric Nonmetric Nonmetric Nonmetric Nonmetric
6B Output power socket (W x H) 35x35 35x35 35x35 35x35 35x35 35x35
6C Input power cord 2.5Sq*3 core 2.5Sq*3 core 2.5Sq*3 core 2.5Sq*3 core 2.5Sq*3 core 2.5Sq*3 core
6D Fuse/MCB switch (W x H) 12 12 85x9 85x9 85x9 85x9
6E No of power sockets 03 03 01 01 01 01
7 Top Cover (L x W) 310 x 190 316 x 190 361x362 380x361 361x400 361x400

[0058] Fig. 3a illustrates an exemplary bottom view of an inverter box in accordance with an embodiment of the present invention.Fig. 3b illustrates an exemplary view of a PCB stand of the inverter box in accordance with an embodiment of the present invention. Fig. 3c illustrates an exemplary left and right-side view of the inverter box in accordance with an embodiment of the present invention.
[0059] Fig. 4a illustrates an exemplary front view of the inverter boxin accordance with an embodiment of the present invention.Fig. 4b illustrates an exemplary rear view of the inverter box in accordance with an embodiment of the present invention.Fig. 4c illustrates an exemplary top view of the inverter box in accordance with an embodiment of the present invention.Fig. 4d illustrates an exemplary perspective view of the inverter box in accordance with an embodiment of the present invention.
[0060] Fig. 5 illustratesan exemplaryperspective view of the inverter box in accordance with an embodiment of the present invention.
[0061] According to an embodiment of the present invention, the inverter box (300) configuration comprises a plurality of sides, denoted as bottom (1), front (2), right-side (4), left-side (5), Right (24), rear (6), and top (7). This spatial arrangement dictates the precise placement of integral components. A battery pack (1B) with a 12V DC voltage is positioned on the bottom plate (1) for 250VA to 100VA while 24V DC voltage is for 1500VA & 2000VA, while a transformer (1A), is responsible for the bidirectional conversion of DC to AC and vice versa via the inverter circuit sub-system (106), is strategically situated alongside and above the battery pack (1B) with the support of a dedicated stand (36). Notably, a DC fan is positioned on the rear panel (6), precisely opposite the heat sink affixed to the inverter circuit board. This configuration enables the expulsion of hot air, optimizing operational efficiency and ensuring safety protocols. Furthermore, the rear panel (6) accommodates the installation of a Miniature Circuit Breaker (MCB) (6E) and a 3-pin Socket (6D), serving the functions of protection and battery charging. On the front panel (2), an LCD display (2A) and an On/Off switch (2B) are positioned, offering real-time insights into a plurality of parameters, comprising battery voltage, temperature, SOC (State of Charge), and manual control. The efficient assembly of these components, aligned in correspondence with the circuit diagram, results in a functional design, accurately reflecting the intended interior configuration.
[0062] Fig. 6 illustrates a graphical representation of sinusoidal waveform of the output of the inverter system in accordance with an embodiment of the present invention. According to an embodiment of the present invention, this graphical representation demonstrates the efficiency of the system in producing a pure sine wave output with minimal harmonic distortion.
[0063] Fig. 7a illustrates a graphical representation of a test report for the 2000VA inverter system in accordance with an embodiment of the present invention. Fig. 7b illustrates a graphical representation of a test report for the 1500VA inverter system in accordance with an embodiment of the present invention. Fig. 7c illustrates a graphical representation of a test report for the 1000VA inverter system in accordance with an embodiment of the present invention.Fig. 7d illustrates a graphical representation of a test report for the 850VA inverter system in accordance with an embodiment of the present invention. Fig. 7e illustrates a graphical representation of a test report for the 500VA inverter system in accordance with an embodiment of the present invention. Fig. 7f illustrates a graphical representation of a test report for the 250VA inverter system in accordance with an embodiment of the present invention
[0064] According to an embodiment of the present invention, the inverter system (100) finds application in uninterruptible power supply (UPS) products, electric vehicles, and portable power solutions.
[0065] Overall, the integrated inverter system of the present invention offers various advantages and distinctive features. Its CCCV charging mechanism within the charger ensures efficient and controlled lithium-ion battery pack charging, extending battery life and optimizing energy usage. The integration of a Battery Management System (BMS) actively safeguards the battery pack, maintaining cell balance and preventing overcharging or over-discharging, thereby enhancing operational safety and overall system performance. The inclusion of an adaptive cooling mechanism, comprising a DC fan and heat sink, effectively dissipates heat from the inverter circuit, battery pack, and charger, leading to sustained operational efficiency and prolonged component longevity. Through predictive maintenance capabilities driven by data analytics and sensor inputs, the system allows proactive monitoring and scheduled maintenance, minimizing unexpected failures and ensuring uninterrupted operation. The modular and scalable design permits customization based on power needs, affording versatility and simplified capacity expansion.
[0066] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof. While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended.
[0067] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.
, Claims:1. An integrated inverter system (100), comprising:
a battery pack (102) comprising a plurality of lithium-ion batteries;
abattery management sub-system (BMS) (104) configured to monitor and regulate the battery pack (102) in real time;
an inverter circuit (106) configured to convert direct current (DC) from the battery pack (102) by a transformer (108) into alternating current (AC) exhibiting a pure sine wave output with a minimal harmonic distortion;
a cooling sub-system (110) configuredto dissipate heat generated by the battery pack (102), the inverter circuit (106), and the transformer (108);
a user interface (112) comprises a display (112a) and an On/Off switch (112b), wherein the display (112a) is configured to provide real-time information on a plurality of parameters of the inverter system (100); and
a charging circuit (114) with Constant Current Constant Voltage (CCCV) charging mechanism is configured to charge the battery pack (104), maintaining its nominal operating conditions.
2. The inverter system as claimed in claim 1, wherein the plurality of lithium-ion batteries are selected from a group comprising at leastone of Lithium Iron Phosphate (LFP), Lithium Cobalt Oxide (LCO), and Lithium Nickel Manganese Cobalt Oxide (NMC);
3. The inverter system as claimed in claim 1, wherein an inverter box (300) comprisesa plurality of vented sections to facilitate heat dissipation and houses an assembly of components comprising the battery pack (102), the transformer (108), the inverter circuit board (106), and a supporting stands (302);
4. The inverter system as claimed in claim 1, wherein the plurality of parameters of the inverter system (100) comprises at least one of a battery voltage, temperature, State of Charge (SOC), and manual switch control.
5. The inverter system as claimed in claim 1, wherein the BMS (104) comprisesa passive balancing module in each of the lithium-ion battery cellsand is configured toprevent overcharging and over-discharging and balances the individual lithium-ion battery cell during the charging and discharging operations.
6. The inverter system as claimed in claim 1, wherein the inverter circuit (106) providesa regulated sinusoidal output voltage and a high input power factor irrespective of voltage fluctuations.
7. The inverter system as claimed in claim 1, wherein the battery pack (102) is arranged in cylindrical, prismatic, or pouch casing.
8. The inverter system as claimed in claim 1, wherein the BMS (104) is further embedded with a Protection Circuit Module (PCM) configured to maintain the battery pack (102) within its operating range and prevent overvoltage, undervoltage, overcurrent, and overtemperature conditions.
9. The inverter system as claimed in claim 1, wherein the cooling sub-system (110) comprises a DC fanpositioned on a back panel (6) of the inverter box (300) and opposite to a heat sink, to exhaust hot air outside for efficient performance and safety controls.
10. The inverter system as claimed in claim 1, wherein the inverter box (300) further includes a top cover (7) with dimensions designed to accommodate the assembled components and facilitate ease of assembly and disassembly.
11. The inverter system as claimed in claim 1, wherein the inverter box (300) includes a front panel (2) with the LCD display (2A), On/Off switch (2B), and other indicators, a bottom panel (1) for placing the battery pack (102), MCB, and 3-pin socket for protection and charging.
12. The inverter system as claimed in claim 1, wherein the inverter circuit (106) comprises super enamel copper round wires or rectangular strips of insulation class "F" or "H" for the transformers (108).
13. The inverter system as claimed in claim 1, further comprisesa fuse/MCB switch (6D) for circuit protection and safety.
14. An inverter circuit (106) for the inverter system, comprising:
an AC mains supply (202) serving as a primary power source, the AC mains supply (202) comprises a power flow bifurcation;
a charger component (204) in communication with the AC mains supply (202), the charger component adapted to receive a portion of power from the AC mains supply (202) and direct the portion of power for charging;
an AC to AC step down converter (204a) with Constant Current Constant Voltage (CCCV) charging feature integrated within the charger component (204), the AC to AC Step Down Converter (204a) adapted to convert incoming AC power to a lower voltage suitable for charging a lithium-ion battery pack (102), the CCCV Charging feature controlling the charging process of the lithium-ion battery pack (102);
the lithium-ion battery (LIB) battery pack (102) is integrated with a battery management system (BMS) (102), thelithium-ion battery pack (102) adapted to receive power from theAC to AC Step Down Converter (204a) and being integrated with the BMS (104), the BMS (102) being configured to monitor and manage the charging process of the lithium-ion battery pack (102);
a DC to AC Step Up Converter (206) component in communication with the lithium-ion battery pack (102), the DC to AC Step Up Converter (206) adapted to convert DC energy from the lithium-ion battery pack (102) into a higher AC voltage suitable for powering loads;
a filter section (208) in communication with the DC to AC Step Up Converter (206), the filter Section (208) is adapted to receive the AC output from the DC to AC Step Up Converter (206) and remove harmonics and noise from the AC output, resulting in a clean sine wave output;
a switching circuit (210) in communication with the filter section (208) is configured to regulate the AC power received from the filter section (208) and delivers AC power to one or more loads, wherein the loads comprise household or electronic devices.