Battery Charging System with Thermal Feedback Control

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Solution Overview

Problem

Battery-operated machines experience downtime due to charging, which reduces productivity, and existing charging systems do not effectively manage heat generated during high-power charging, potentially leading to battery temperature issues.

Innovation Solution

A charging system with a heat rejection element, temperature sensor, and controller that adjusts electrical current based on charging receptacle temperature to prevent overheating, ensuring safe and efficient charging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If high power and electrical current are used to provide a higher charging rate, then charging speed is improved, but heat generation due to electrical resistance increases

Engineering Contradiction:

Improvecharging speedVSAvoidcharging receptacle temperature

Core Design Contradiction:

SpeedVSTemperature

Solution Approach 1:

The charging system incorporates a temperature sensor that continuously monitors the charging receptacle temperature and feeds this information back to the controller. The controller adjusts the charging current based on the temperature feedback, reducing current when temperature exceeds thresholds and restoring it when temperature is acceptable, thereby managing heat generation while maintaining charging speed

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The charging system dynamically adjusts the charging current based on real-time temperature conditions. The controller modulates the charging rate between high and low levels depending on whether the temperature is within acceptable ranges or exceeds thresholds, making the charging process adaptive rather than static

Inventive Principle:

Principle #15Dynamics

2Reliability

If periodic charging is performed to replenish battery energy, then battery operation is maintained, but machine downtime increases

Engineering Contradiction:

Improvebattery operation continuityVSAvoidmachine productivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system enables continuous or near-continuous charging operations by quickly adjusting charging rates based on temperature. When temperature is acceptable, charging proceeds at high rates; when temperature exceeds thresholds, charging is temporarily reduced or paused. This minimizes interruptions and keeps the charging action continuous rather than intermittent

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The charging system changes operational parameters (charging current and power levels) based on temperature conditions. By dynamically adjusting these parameters, the system optimizes charging efficiency while preventing overheating, thereby reducing overall charging time and minimizing machine downtime

Inventive Principle:

Principle #35Parameter changes

3Temperature

If charging current is reduced to prevent overheating, then temperature control is improved, but charging rate decreases

Engineering Contradiction:

Improvecharging receptacle temperature controlVSAvoidcharging rate

Core Design Contradiction:

TemperatureVSSpeed

Solution Approach 1:

The charging system employs periodic adjustments to charging current based on temperature monitoring. When temperature exceeds thresholds, the system periodically reduces or pauses charging current to allow cooling. When temperature returns to acceptable levels, charging current is restored. This periodic on-off or modulated charging pattern manages temperature while maintaining overall charging progress

Inventive Principle:

Principle #19Periodic action

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 system reduces downtime by optimizing charging rates based on temperature, enhancing safety and productivity by preventing battery overheating and extending battery life.

Implementation Method 1

a heat rejection element thermally coupled to the charging receptacle

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a temperature sensor, and a charging controller operatively coupled to the temperature sensor and the charging receptacle. The charging controller is configured to receive a temperature signal from the temperature sensor, the temperature signal being indicative of a charging-receptacle temperature

Methodology Applied

Scientific EffectThermal detection: Temperature Gradient

Implementation Method 3

the high power and electrical current used to provide a higher charging rate create heat due to electrical resistance

Methodology Applied

Scientific EffectElectrical resistance heating: Joule Heating

Data Source

PatentUS11616380B2Charging system for a battery operated machine

Publication Date: 2023.03.28 CATERPILLAR INC

AI summary

A charging system for a battery-operated machine is disclosed. The charging system includes a charging receptacle having a power connection and a signal connection, with the charging receptacle configured to receive electrical current via the power connection from a power supply plug. The charging system further includes a heat rejection element thermally coupled to the charging receptacle, a temperature sensor, and a charging controller operatively coupled to the temperature sensor and the charging receptacle. The charging controller is configured to receive a temperature signal from the temperature sensor, the temperature signal being indicative of a charging-receptacle temperature. The charging controller is further configured to transmit, via the signal connection to the connected plug, a control signal to adjust (e.g., raise or lower) the electrical current supplied to the power connection.