Auxiliary Battery Charger Power Limit Control for Shared Vehicle Circuits
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Solution Overview
Problem
Liftgate battery chargers lack current control mechanisms, leading to blown truck fuses and failed ABS system tests due to excessive power draw from shared auxiliary power lines, resulting in increased maintenance and downtime.
Innovation Solution
A battery charger that controls charge power based on available current inputs and conditions, performing a power limit test to determine safe charging levels and communicating diagnostic information via CAN bus or Bluetooth, allowing for improved system health monitoring and reduced downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the battery charger draws maximum current to charge the auxiliary battery quickly, then the charging speed is improved, but the truck fuses are blown and ABS system tests fail
Solution Approach 1:
The battery charger dynamically adjusts its current draw based on real-time monitoring of the auxiliary power line conditions. The system transitions from a static maximum current draw approach to a dynamic adaptation strategy where the charging current is modulated according to the available power capacity, preventing fuse blows while maximizing charging efficiency under varying conditions.
Solution Approach 2:
The system implements feedback control by continuously monitoring the auxiliary power line current and voltage levels, then adjusting the charging current accordingly. This closed-loop control prevents excessive current draw that would blow fuses or interfere with ABS tests, while still achieving efficient charging when power availability permits.
2Device complexity
If the battery charger operates without current control mechanisms, then the device complexity is reduced, but blown fuses and failed diagnostic tests occur
Solution Approach 1:
The battery charger performs self-diagnosis and self-regulation by automatically monitoring the auxiliary power line conditions and adjusting its own current draw without external intervention. This self-service capability prevents fuse blows and diagnostic test failures while maintaining relatively simple system architecture, as the charger manages its own power consumption autonomously.
3Difficulty of detecting and measuring
If the battery charger performs power limit tests and diagnostic monitoring, then the ability to diagnose trailer systems is improved, but the device complexity increases
Solution Approach 1:
The battery charger is designed with multi-functionality, serving both as a power charging device and a diagnostic monitoring system. By integrating diagnostic capabilities into the existing charger architecture, the system can perform power limit tests, monitor auxiliary power line conditions, and provide system health information without requiring entirely separate diagnostic equipment, thus balancing enhanced diagnostic capability with controlled complexity.
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 reduces downtime and maintenance hours by preventing blown fuses and failed diagnostic tests, enhancing the ability to diagnose trailer systems and ensuring safe and efficient charging of liftgate batteries.
Implementation Method 1
performing a power reversal to supply electrical power from an auxiliary battery of the vehicle to one or more vehicle components
Data Source
AI summary
A method of determining a power draw limit of a battery charger of a vehicle includes performing a power reversal to supply electrical power from an auxiliary battery of the vehicle to one or more vehicle components, measuring electrical power supplied to the one or more vehicle components by the auxiliary battery, determining validity of the measurement, and in response to the determining the validity of the measurement, determining the power draw limit based on the measured electrical power and a power limit of a vehicle circuit coupled to the battery charger.