24V Vehicle Rescue Circuit Using Boosted Supercapacitor Startup
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Solution Overview
Problem
Industrial vehicles powered by 24V rechargeable batteries face issues where power leakage or a broken battery prevents the motor from starting, as the total voltage drops, and existing rescue devices are inadequate in addressing these shortcomings.
Innovation Solution
A rescue device that electrically connects a vehicle battery pack and electrical control device in parallel, incorporating a booster module, supercapacitor module, relays, and a rescue control module to boost voltage and charge a supercapacitor, which then supplies power to the vehicle electrical control device, enabling vehicle startup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional 24V rechargeable batteries are used to power industrial vehicles, then the vehicle can operate with a simple battery system, but the system becomes unreliable when power leakage or battery failure occurs causing total voltage drop and motor inability to start
Solution Approach 1:
A supercapacitor module is introduced as an intermediary energy storage device between the battery pack and the motor control system. The supercapacitor provides rapid discharge capability to supply high current during motor startup, while the battery pack handles steady-state power supply. This intermediary component resolves the contradiction by enabling reliable startup without requiring the battery system to directly provide high surge currents, thus maintaining system reliability while managing complexity through functional separation.
Solution Approach 2:
The power supply system is segmented into two functional modules: a battery pack for steady-state power supply and a supercapacitor module for transient high-power delivery during startup. This segmentation allows each component to operate in its optimal performance range, with the battery providing stable voltage and the supercapacitor providing high current pulses, thereby improving overall system reliability without requiring a single complex battery system to handle all demands.
2Reliability
If a booster module and supercapacitor module are added to the rescue device, then the voltage boosting capability and power supply reliability are improved, but the device complexity and number of components increase
Solution Approach 1:
The rescue device integrates multiple functions into a unified system: the booster module not only boosts voltage from 12V to 24V but also charges the supercapacitor module; the control module performs both voltage monitoring and relay control functions; and the supercapacitor module serves both as an energy storage device and a voltage stabilization component. This multi-functionality reduces the need for separate dedicated components for each function, thereby improving power supply reliability while managing device complexity through functional integration.
3Power
If the booster module boosts voltage to charge the supercapacitor module, then the power supply capability is improved, but the energy loss during voltage conversion increases
Solution Approach 1:
The booster module is designed to automatically activate when the control module detects low voltage in the battery pack, and automatically deactivate when the supercapacitor module reaches full charge. This self-service operation eliminates the need for continuous monitoring and manual intervention, reducing energy waste from prolonged boosting operation. The system serves itself by autonomously managing the charging process, thereby improving power supply capability while minimizing energy loss through precise control.
4Measurement precision
If relays are used to control the switching between battery pack and supercapacitor module, then the control precision and power distribution accuracy are improved, but the device complexity and potential failure points increase
Solution Approach 1:
The control module continuously monitors the voltage levels of both the battery pack and supercapacitor module, and uses this feedback information to intelligently control the relays. When the supercapacitor voltage reaches a predetermined threshold, the control module automatically switches the power source from the battery pack to the supercapacitor module. This feedback-based control ensures precise voltage detection and accurate power distribution while reducing the need for complex manual relay control mechanisms, thereby improving measurement precision while managing device complexity through automated decision-making.
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 solution effectively rescues vehicles by boosting voltage to 24V, ensuring power supply to the vehicle electrical control device even in low voltage or battery failure scenarios, facilitating vehicle startup and providing a method for user interface monitoring of the recharging state.
Implementation Method 1
a booster module, a supercapacitor module, a first relay, a second relay, a third relay, a first positive-electrode circuit, a second positive-electrode circuit, a negative-electrode circuit, and a rescue control module. The rescue control module acquires a power from the vehicle battery pack via the second positive-electrode circuit based on a low voltage of the vehicle battery pack and boosts an output voltage to charge the supercapacitor module via the booster module.
Data Source
AI summary
A rescue device of boosting 24 volts to a supercapacitor for vehicle(s) and a method of controlling the same, the rescue device is electrically connected a circuit system in which a vehicle battery pack and a vehicle electrical control device are connected parallelly. The rescue device includes a booster module, a supercapacitor module, a first relay, a second relay, a third relay, a first positive-electrode circuit, a second positive-electrode circuit, a negative-electrode circuit, and a rescue control module. The rescue control module acquires a power from the vehicle battery pack via the second positive-electrode circuit based on a low voltage of the vehicle battery pack and boosts an output voltage to charge the supercapacitor module via the booster module. After the supercapacitor module is rechargeable completely, it supplies the power via the first positive-electrode circuit to start the vehicle electrical control device, thus rescuing the vehicle.