Battery Charge Control Using a Resistor Grid Before Regen Events
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Solution Overview
Problem
Existing electric drive machines face challenges in efficiently managing battery state of charge, particularly during downhill haul events, leading to potential wear and tear of friction-based brakes and inefficiencies in energy dissipation.
Innovation Solution
A control circuit is implemented to determine the battery's state of charge and a target state of charge, controlling the flow of electrical current to a resistor grid to modify the battery's charge before anticipated events, such as downhill hauls, by dissipating excess charge as heat through the resistor grid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the battery state of charge is increased to maximize energy availability, then the energy storage capacity is improved, but the battery lifespan and safety deteriorate due to overcharging and excessive charge events
Solution Approach 1:
The control circuit proactively manages battery charge state by discharging the battery before anticipated charge events (such as downhill hauls) occur. This preliminary action prevents the battery from reaching dangerous charge levels during regenerative braking events, thereby extending battery lifespan while maintaining energy availability for productive work.
2Loss of energy
If regenerative braking events are allowed to charge the battery freely, then energy recovery is improved, but harmful thermal events and safety risks worsen due to excessive charge events
Solution Approach 1:
The control circuit continuously monitors the battery's state of charge and uses this feedback to determine when to discharge the battery through the resistor grid. This feedback mechanism ensures that the battery charge state remains within safe operating limits, preventing thermal events while maximizing energy recovery during regenerative braking by allowing charge events only when the battery has sufficient headroom.
3Productivity
If the battery charge state is optimized for maximum performance, then the productivity is improved, but the device complexity worsens due to additional control mechanisms
Solution Approach 1:
The control circuit performs multiple functions: it monitors battery state of charge, predicts upcoming charge events based on operational conditions, determines optimal discharge timing, and controls the resistor grid. This multi-functionality allows the system to optimize battery performance and extend battery lifespan without requiring separate dedicated systems for each function, thereby managing complexity efficiently.
4Reliability
If excess energy is dissipated through the resistor grid before charge events, then the battery safety is improved, but the energy efficiency worsens due to energy loss as heat
Solution Approach 1:
The control circuit applies preliminary anti-action by discharging the battery before anticipated charge events occur. This proactive discharge prevents the battery from reaching dangerous charge levels during regenerative braking, thereby ensuring battery safety. The energy dissipated as heat during this preliminary discharge is a controlled loss that prevents much larger energy losses and safety hazards that would occur without this preventive measure.
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
This approach optimizes battery state of charge, reduces wear on friction-based brakes, and enhances energy management by effectively dissipating excess electrical charge as heat, improving the efficiency and longevity of the electric drive machine.
Implementation Method 1
control a flow of electrical current from the battery to the resistor grid, to modify the state of charge of the battery to the target state of charge, prior to the anticipated charge event
Data Source
AI summary
Provided herein is an electric drive machine including a battery having a state of charge ranging from a depleted state to a full state; a resistor grid electrically coupled to the battery; and a control circuit comprising one or more processors and a memory structured to store instructions that, when executed by the one or more processors, cause the control circuit to: determine the state of charge of the battery; determine a target state of charge of the battery according to an anticipated charge event; and control a flow of electrical current from the battery to the resistor grid, to modify the state of charge of the battery to the target state of charge, prior to the anticipated charge event.