Battery Charging Controller for Work Machines
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Solution Overview
Problem
Battery-operated work machines experience downtime during charging, leading to reduced productivity due to the time-consuming nature of the charging process, which is not efficiently managed by existing technologies.
Innovation Solution
A system comprising a charger, charging receptacles, power supply connectors, and a charging controller that determines and supplies the maximum possible power to the battery unit in the shortest possible time based on its net charge capacity, optimizing the charging process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery-operated machine is charged using conventional charging methods, then the battery unit is charged, but the machine experiences downtime and reduced productivity
Solution Approach 1:
The system performs preliminary actions by establishing multiple charging connections simultaneously before the battery is fully depleted, rather than waiting for traditional single-connection charging to complete. The charging controller proactively manages multiple chargers to begin charging at different rates based on battery state, reducing overall charging time and minimizing machine downtime.
Solution Approach 2:
The charging process is segmented into multiple parallel charging connections, each handled by separate chargers. Instead of using one charging path, the system divides the charging load across multiple independent charging circuits, allowing simultaneous charging operations that collectively reduce total charging time while maintaining battery safety through controller management.
2Loss of time
If maximum power is supplied to charge the battery unit rapidly, then charging time is reduced, but the battery unit may be damaged due to excessive power input
Solution Approach 1:
The charging controller dynamically adjusts the power distribution across multiple charging connections based on real-time battery state monitoring. As the battery charges, the controller modulates each charger's output power to prevent overheating or overcharging, enabling rapid charging while maintaining battery safety through continuous adaptive control rather than static maximum power input.
Solution Approach 2:
The system implements feedback control where the charging controller continuously monitors battery parameters (temperature, voltage, charge level) and adjusts the power supplied by each charger accordingly. This closed-loop control ensures that maximum power is delivered when safe, while automatically reducing power if battery conditions indicate potential damage, thus achieving fast charging without compromising battery reliability.
3Speed
If multiple chargers are used to charge the battery unit simultaneously, then charging speed increases, but the system complexity increases
Solution Approach 1:
The charging controller serves multiple functions: it manages multiple independent charging connections, monitors battery state, distributes power dynamically, and ensures safety compliance. By making the controller multi-functional, the system achieves complex rapid charging capabilities without proportionally increasing overall system complexity, as one component performs multiple critical roles.
Solution Approach 2:
The system merges multiple charging functions into a unified control architecture where a single charging controller manages all charging connections. Instead of having separate control systems for each charger, the functions of multiple chargers and their coordination are combined under one intelligent controller, simplifying the control structure while enabling sophisticated power management across multiple charging paths.
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 solution minimizes downtime by rapidly charging the battery unit, thereby enhancing the operational efficiency and productivity of battery-operated work machines by ensuring they can return to operation as soon as possible.
Implementation Method 1
at least one charger to charge the battery unit
Data Source
AI summary
A system for charging a battery unit to power a work machine. The system includes a charger to charge the battery unit, charging receptacles, power supply connectors, and a charging controller. The power supply connectors are configured to be received into the charging receptacles to attain connections between the charger and the battery unit. The charging controller is communicably coupled to the charger and is configured to receive an input corresponding to a net charge capacity of the battery unit; determine a power to be supplied to the battery unit by the charger to charge the battery unit in response to the input; and supply the power to the battery unit from the charger through the connections. The power to be supplied to the battery unit corresponds to a maximum possible power that meets the net charge capacity of the battery unit in the shortest possible time.