Battery formation power supply
Core Working Principle: The Precision Charging/Discharging "Battery Activator"
Core Tasks:
- Formation: Performing the first precisely controlled charge/discharge cycle on newly electrolyte-filled batteries to form a stable SEI film (Solid Electrolyte Interphase) on the electrode surfaces. The SEI film is crucial for battery safety, cycle life, and performance.
- Capacity Grading / Sorting: Testing the capacity of batteries that have completed formation, sorting them according to their actual discharge capacity to ensure consistent performance within a batch.
- Parameter Monitoring: Real-time monitoring and recording of key parameters such as voltage, current, temperature, and internal resistance during charge/discharge.
Workflow:
- Charging: Provides precisely controlled DC current.
- Discharging: Absorbs the energy released by the battery (key differentiator).
- Traditional Dissipative Type: Converts discharge energy into heat via power resistors. Disadvantages: Extremely low efficiency (<50%), massive energy consumption, significant heat generation affecting environmental control and increasing cooling costs.
- Regenerative Type (Mainstream & Trend): Converts battery discharge energy back into AC grid power or to other equipment for reuse via high-efficiency inverters.
- Topology: Typically employs PWM rectifier/inverter technology (e.g., Three-Phase VIENNA Rectifier, Three-Level NPC/T-Type).
- Advantages: High efficiency (>90% possible), significant energy savings (>60% reduction), low heat generation, reduced operating costs, environmentally friendly.
System Architecture: Modular, Intelligent, High-Efficiency Design
System Level (Control & Power Distribution):
- Master Control System (HMI/SCADA): Central monitoring software for recipe management, task scheduling, real-time monitoring, data storage & analysis, alarm management, and user interface.
- AC Distribution Cabinet: Grid input connection, main circuit breakers, surge protection, main energy metering.
- DC Bus: (For centralized regenerative systems) Aggregates energy from multiple regenerative modules for unified feedback to the grid.
Channel Control Level (Core Execution Unit):
- Regenerative Power Module:
- DC/DC Converter Module:
- Channel Controller: Dedicated controller per channel, receives commands from the upper level, performs real-time closed-loop control of channel charge/discharge current/voltage, executes protection logic (over-voltage, under-voltage, over-current, over-temperature), collects battery data and status.
Rectifier Side (AC/DC): Converts grid AC to a stable DC bus voltage (typically 600V-800V). Uses PWM rectification for high power factor (PF>0.99) and low current harmonic distortion (THDi<3%).
Regenerative Discharge Side (DC/AC): Inverts battery discharge energy (DC) into AC synchronized with the grid frequency and phase for feedback. Uses high-efficiency, high-reliability IGBT/SiC MOSFET modules and advanced modulation strategies.
Bidirectional DC/DC: Connects between the DC bus and the battery, enabling precise control of charge/discharge current and bi-directional energy flow. Core component for control precision and profile execution. Employs techniques like multi-phase interleaving, soft-switching (LLC, PSFB) for higher efficiency and power density.
Auxiliary Systems:
- Cooling System: Liquid cooling has become the absolute mainstream (especially in high-power-density equipment), replacing air cooling. Offers high efficiency, low noise, and good temperature uniformity.
- CAN/Ethernet Communication Network: Enables high-speed, reliable communication between all levels.
- Battery Tray/Fixture: Ensures reliable connection, low contact resistance, and facilitates automated loading/unloading.
Core Hardware Technology Evolution:
- Power Devices: IGBT dominant, accelerated adoption of SiC MOSFETs in high-end, high-power-density devices (offering significant high-frequency/high-efficiency advantages).
- Topology: Three-level topologies (T-Type, NPC) widely used to improve efficiency and reduce harmonics/switching losses.
- Cooling: Liquid cooling (water/water-glycol) applied to power modules, inductors, busbars, and other heat-generating components.
Market Development Trends: High Growth, Intelligence, Green Transformation, Localization
Drivers & Market Growth:
- EV Boom: Surging demand for power batteries is the largest engine.
- ESS Market Rise: Rapid growth in electrochemical energy storage installations generates massive demand.
- Sustained Consumer Electronics Demand: Steady shipments of phones, laptops, TWS earphones, etc.
- New Battery Technology Industrialization: Industrialization of Sodium-ion, Solid-state batteries, etc., creates incremental equipment demand.
- Industry Forecast: The global lithium battery formation power market is expected to maintain a CAGR exceeding 20% over the next 5 years, with China being the largest and fastest-growing market (hosting the majority of global capacity).
Core Technology Trends:
- High Efficiency & Energy Savings (Top Priority):
- High Precision & Intelligence:
- High Power Density & Miniaturization:
- High Reliability & Maintenance-Free Operation:
- Platformization & Compatibility:
Regenerative Systems Become Absolute Mainstream & Standard Requirement: Driven by policies (e.g., China's "Dual Carbon" goals) and cost pressure, penetration exceeds 90%.
Accelerating SiC Device Adoption: Significantly reduces switching losses, improves efficiency and power density; becoming standard in high-end equipment. Cost reductions will further drive adoption.
Efficient Topology & Control Algorithm Optimization: Continuous optimization of topologies (e.g., hybrid multi-level), soft-switching techniques, modulation strategies (e.g., DPWM, optimized SVPWM) to enhance system efficiency.
AI Algorithm Application: Using AI to optimize charge/discharge profiles (shortening formation time), predict battery performance/life, enable intelligent sorting, and early defect detection (improving yield).
Big Data & Deep MES Integration: Seamless integration of equipment data with factory MES systems for full-process digitalization, traceability, and closed-loop quality management.
Higher Precision: Higher accuracy current/voltage sampling and control (μV/mA level) to meet high-consistency battery production requirements.
Integrated Module Design: High integration of channel functional modules (power, control, sensing).
Liquid Cooling Pervasiveness: Key enabling technology for compact, high-power-density designs.
Redundancy Design: Redundancy for critical components (e.g., fans, power modules).
Predictive Maintenance: AI-based predictive maintenance using operational data to reduce downtime risk.
Modular Design: Supports rapid replacement of faulty modules, minimizing downtime.
Single Platform Compatibility for Diverse Battery Types: Adapts to diverse needs (LFP, NCM, Sodium-ion, etc.).
Strong Software Configurability: Software-defined adaptability to different recipes and process changes.
Competitive Landscape & Localization:
- High Localization Rate: Chinese companies dominate the global market, with technological capabilities rapidly closing the gap or achieving parity/leadership in specific areas (especially cost, responsiveness, service).
- International Players: Bitrode (US), AVL (Austria), Digatron (Germany), PEC (Korea) retain influence in specific high-end segments or overseas markets.
- Competitive Focus: Technological advancement (efficiency, precision, intelligence), cost competitiveness, delivery capability, global service capability.
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