Work Machine Battery Charge Modes for Lifespan and Power Availability
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Solution Overview
Problem
Existing battery management systems for work machines fail to efficiently manage battery charge when disconnected from a power source, leading to reduced battery lifespan due to extreme discharge or charge levels.
Innovation Solution
A control system that switches between primary and secondary power modes to maintain battery charge within specific setpoints, adjusting power distribution to extend battery life and ensure sufficient charge when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery charge is maintained at high levels to ensure sufficient power availability when disconnected from a power source, then the power availability is improved, but the battery lifespan is reduced due to extended periods at high charge levels
Solution Approach 1:
The patent implements dynamic battery charge management by switching between different charge setpoints based on operational mode. In primary power mode, the battery is maintained at a first charge setpoint (e.g., 50-70% charge) to extend lifespan. When a modification request is received indicating need for enhanced power availability, the system switches to a second charge setpoint (e.g., 80-100% charge). This dynamic adjustment resolves the contradiction by adapting the charge level to actual operational needs rather than maintaining a static high charge level.
Solution Approach 2:
The system changes the battery charge parameter (state of charge setpoint) based on operational requirements. The control system monitors power availability and operational mode, then adjusts the target charge level accordingly. This parameter change allows the battery to operate at lower charge levels during normal operation (preserving lifespan) while achieving high charge levels when sufficient power availability is required, thus resolving the technical contradiction.
2Duration of action of stationary object
If the battery charge is maintained at low levels to extend battery lifespan, then the battery lifespan is improved, but the power availability when disconnected from a power source is reduced
Solution Approach 1:
The system dynamically adjusts the battery charge setpoint based on operational mode and power availability requirements. Rather than maintaining a permanently low charge level, the system switches to a higher second charge setpoint when a modification request is received, ensuring sufficient power availability while maintaining low charge levels during normal operation to preserve battery lifespan.
Solution Approach 2:
The system performs preliminary charging to a higher setpoint in response to a modification request before the work machine actually needs to operate independently. This preliminary action ensures that when disconnection from the power source occurs, the battery already has sufficient charge to provide adequate power availability, thus resolving the contradiction between lifespan and power availability.
3Productivity
If frequent charge and discharge cycles are allowed to maximize battery utilization, then the productivity is improved, but the battery lifespan is reduced due to increased cycle wear
Solution Approach 1:
The system applies partial charging action by maintaining the battery at a first charge setpoint (partial charge, e.g., 50-70%) during primary power mode rather than allowing complete discharge cycles. This partial action approach maximizes battery utilization for daily operations while avoiding the excessive wear associated with frequent full charge-discharge cycles, thus resolving the contradiction between productivity and lifespan.
Data Source
AI summary
Systems and methods for managing a battery charge of a work machine are described herein. The battery charge is maintained using a source of power (or other source) while the work machine also uses the source of power to power the work machine and the systems associated with the work machine. In instances in which the source of power may be removed for use by the work machine, a modification request may be used to change the battery from primary mode of operation, where the battery charge is maintained at a lower level to maintain the life of the battery, to a secondary mode of operation where the battery is charged to a high charge. The higher charge can be used to accommodate work machine operations while the battery is removed from the source of power. The battery can thereafter be returned to the primary mode of operation.