AGV Battery Charging Management with Dynamic Voltage Adjustment
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Solution Overview
Problem
The existing battery charging systems for automated guided vehicles require costly replacements and voltage adjustments when switching between lead-acid and lithium ion batteries, and the use of ID tags can lead to overcharging and increased costs.
Innovation Solution
A battery charging management system that allows for the sequential conversion of lead-acid batteries to lithium ion batteries and uses a single automatic battery charger with a DC power supply capable of boosting voltage, enabling efficient charging without the need for type-specific chargers or ID tags, thereby reducing costs and preventing overcharging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the automatic battery charger is exchanged to one having a power supply unit with maximum charging voltage adjusted for lithium ion battery, then the lithium ion battery can be charged properly, but the costs increase significantly
Solution Approach 1:
The power supply unit is designed with a switchable voltage output that can dynamically adjust between 28V (for lead-acid batteries) and 42V (for lithium ion batteries) based on the battery type detected by the identification unit. This dynamic voltage adjustment allows a single charger to serve multiple battery types without requiring separate charging stations for each battery type.
Solution Approach 2:
The automatic battery charger is designed with universal compatibility to charge both lead-acid batteries and lithium ion batteries using the same device. The identification unit detects the battery type, and the control unit automatically selects the appropriate charging voltage, making the charging station multi-functional and eliminating the need for separate charging infrastructure.
2Adaptability or versatility
If ID tag is installed to identify battery type, then charging voltage can be adjusted appropriately, but both battery and battery charger costs increase
Solution Approach 1:
The battery unit itself contains the identification unit that automatically identifies its own battery type (lead-acid or lithium ion) and communicates this information to the charging station. This self-identification eliminates the need for external ID tags or manual intervention, reducing system complexity and cost while maintaining accurate battery type recognition.
3Adaptability or versatility
If voltage switching control is provided in the automatic battery charger, then charging voltage can be adjusted for different battery types, but costs increase
Solution Approach 1:
The power supply unit incorporates a switchable voltage parameter that can change between 28V and 42V based on battery type. This parameter change is achieved through a simple switching mechanism controlled by the control unit, which selects the appropriate voltage level without requiring complex voltage regulation circuits or multiple power supply units, thereby minimizing cost increase.
4Ease of manufacture
If a single automatic battery charger is used for both lead-acid and lithium ion batteries, then costs are reduced, but voltage compatibility becomes challenging
Solution Approach 1:
The identification unit provides feedback about the battery type (lead-acid or lithium ion) to the control unit, which then automatically adjusts the power supply unit's output voltage to the appropriate level (28V for lead-acid, 42V for lithium ion). This feedback mechanism ensures voltage compatibility is maintained automatically, eliminating the need for manual voltage adjustment or separate charging stations.
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
Enables cost-effective charging of both lead-acid and lithium ion batteries using existing infrastructure, extends the service life of lithium ion batteries by maintaining an optimal voltage range, and avoids the need for expensive device replacements.
Implementation Method 1
a DC power supply unit 21 capable of boosting a voltage value
Data Source
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AI summary
Disclosed is a battery charging management system of an automated guided vehicle that travels in an unpiloted manner by using a mounted battery as a driving source, the mounted battery being charged in a charging station, wherein a battery charging controller that monitors a remaining capacity of the mounted battery is mounted on the automated guided vehicle, the battery charging controller starts a charging operation for the mounted battery in the charging station when the remaining capacity of the battery is lower than a predetermined value, and a charging route of the vehicle is cut off when a charging amount of the mounted battery reaches a predetermined capacity during the charging operation.