Centralized Battery Charger Control for Mixed Lithium and Lead-Acid Fleets
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Solution Overview
Problem
Existing systems lack an efficient method to control and manage the charging of large numbers of rechargeable lithium and lead batteries used in industrial trucks, which can lead to deviations from optimal charging curves, reducing battery lifespan and requiring manual intervention.
Innovation Solution
A centralized control device that processes status information from multiple charging devices to generate control data, optimizing the charging process for lithium and lead batteries by using normative charging curves and dynamic power allocation, ensuring efficient and prioritized charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual intervention is used to monitor and control charging of multiple batteries, then charging processes can be adjusted in real-time, but labor costs increase and response time decreases
Solution Approach 1:
The charging devices are equipped with autonomous control capabilities where the processor device automatically generates control data based on status information from multiple charging devices. The system self-regulates charging processes without manual intervention, with each charging device monitoring its own status and receiving appropriate control commands autonomously.
Solution Approach 2:
The control system is designed to manage multiple types of batteries (lithium and lead batteries) using a single unified processor device. The system handles diverse charging requirements through universal control algorithms that adapt to different battery chemistries and charging curves, eliminating the need for separate control systems for each battery type.
2Reliability
If standard charging curves are strictly enforced for lead batteries, then battery lifespan is extended, but charging flexibility is reduced
Solution Approach 1:
The control system dynamically adjusts charging parameters based on real-time status information from charging devices. While standard charging curves serve as the foundation for lead battery charging to ensure longevity, the system can dynamically modify charging current and voltage within acceptable ranges to respond to changing battery conditions, ambient temperature, and power availability.
Solution Approach 2:
The processor device modifies charging parameters such as current, voltage, and power levels based on the specific battery type and its current state. For lead batteries, the system maintains adherence to normative charging curves by adjusting parameters within defined boundaries, while for lithium batteries, it applies different parameter sets optimized for their charging characteristics.
3Productivity
If multiple charging devices operate independently without centralized control, then system simplicity is maintained, but charging efficiency decreases and power allocation is suboptimal
Solution Approach 1:
The centralized control system is segmented into distributed components where each charging device operates as an independent node that reports status information to the processor device. The processor device segments the charging fleet into different groups (lithium vs. lead batteries) and applies appropriate control strategies to each segment, managing complexity through hierarchical organization.
Solution Approach 2:
The system implements continuous feedback loops where charging devices transmit status information (charge level, current, voltage, temperature) to the processor device, which then generates updated control data based on this feedback. This closed-loop control enables real-time optimization of charging efficiency while maintaining system stability and preventing deviations from optimal charging curves.
4Loss of time
If charging priority is assigned to specific batteries, then critical batteries are charged first, but fairness in resource allocation is reduced
Solution Approach 1:
The system performs preliminary actions by pre-configuring priority levels for different battery types and applications. Lithium batteries and those with higher operational criticality are assigned higher priorities in advance, allowing the processor device to automatically allocate charging resources according to these pre-established rules without requiring real-time decision-making, thus maintaining both efficiency and perceived fairness.
Data Source
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AI summary
The invention relates to a device (110) and a method for controlling a plurality of charging devices (120a-d) comprising a plurality of first charging devices (120a,b) for charging a plurality of rechargeable lithium batteries and a plurality of second charging devices (120c,d) for charging a plurality of rechargeable lead-acid batteries. The device (110) includes a communication interface (113) configured to receive status information about the charging status of each charging device (120a-d) electrically connected to a respective battery via a data connection. Furthermore, the device (110) includes a processor (111) configured to generate control data for the plurality of charging devices (120a-d), wherein the control data is configured to control the charging process of each charging device (120a-d).The processor (111) is configured to generate control data for the plurality of first charging devices (120a,b) based on the status information of the plurality of second charging devices (120c,d). The communication interface (113) is further configured to transmit the control data to the plurality of charging devices (120a-d).