Assembly Line Battery Charging With Segmented Power Control
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Solution Overview
Problem
Existing vehicle battery charging systems require specific charging locations and add space burdens to the assembly process, while also being inefficient due to regulatory constraints on battery charge levels during transport.
Innovation Solution
An apparatus and method for assembly line charging of vehicle batteries using a stationary power transmitter line, where processing circuitry receives battery data, calculates and evaluates battery charge, and adjusts power supply to optimize power distribution and prevent overcharging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vehicles are charged at specific charging locations after assembly, then vehicle batteries can be charged to sufficient level for performance evaluation, but additional space burden is added to the assembly process
Solution Approach 1:
The charging system is segmented into multiple linear sections along the assembly line, with each section independently controllable. This allows charging to occur at multiple distributed locations rather than requiring a single centralized charging station, thereby reducing the total space burden while maintaining adequate charge levels for vehicle performance evaluation
Solution Approach 2:
Vehicles are charged preliminarily during the assembly line process itself, before reaching the evaluation stage. This preliminary charging action eliminates the need for separate post-assembly charging locations, as vehicles arrive at the evaluation stage already charged to the required level
2Productivity
If batteries are transported with charge exceeding predefined level, then charging efficiency improves, but regulatory constraints are violated
Solution Approach 1:
The power supply to each linear section is dynamically adjusted based on real-time evaluation of vehicle battery charge levels. This dynamic control allows the system to optimize charging efficiency by supplying power only when and where needed, while automatically preventing overcharging that would violate regulatory constraints during transport
Solution Approach 2:
The system continuously evaluates vehicle battery charge levels and uses this feedback to adjust power supply to linear sections. This feedback mechanism ensures regulatory compliance by preventing batteries from exceeding predefined charge levels during transport, while maintaining high charging efficiency by directing power to vehicles that need it
3Reliability
If dwell charging stations are used for vehicle battery charging, then complete charging is achieved, but non-value added time increases
Solution Approach 1:
Charging is performed continuously during the assembly line process rather than in separate dwell periods. Vehicles receive power as they move through the assembly line, eliminating idle dwell time at charging stations while ensuring complete charging is achieved before vehicles leave the facility
Solution Approach 2:
Charging is performed preliminarily during assembly operations, so vehicles are fully charged before reaching evaluation or delivery stages. This preliminary charging action eliminates the need for separate dwell charging stations, as the charging function is integrated into the continuous assembly line flow
Data Source
AI summary
The present disclosure relates to an apparatus and method for assembly line charging of vehicle batteries. In an embodiment, the method includes receiving battery data of a plurality of vehicle batteries on an assembly line, the received battery data including electric charge data of each vehicle battery of the plurality of vehicle batteries, each of the plurality of vehicle batteries being powered by a corresponding linear section of a stationary power transmitter line, calculating a vehicle battery charge of each of the plurality of vehicle batteries based on the received electric charge data, evaluating the calculated vehicle battery charge of each of the plurality of vehicle batteries relative to associated vehicle battery charge parameters, and adjusting a power supplied to the corresponding linear section of the stationary power transmitter line based on the evaluation of the calculated vehicle battery charge of each of the plurality of vehicle batteries.