Construction Machine Battery Charging Profiles for Accurate Time Prediction
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Solution Overview
Problem
Construction machinery powered by electric energy lacks accurate prediction of battery charging time, necessitating a solution to inform users of the exact charging duration for improved convenience.
Innovation Solution
A battery charging device with a power distribution system and battery management system that calculates a charging profile with multiple constant current sections, adjusting charging rates based on battery operation limits and temperature, to predict and notify users of the charging time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a standard constant current charging method is used, then the charging process is simple, but the charging time cannot be accurately predicted or optimized
Solution Approach 1:
The charging process is divided into multiple constant current charging sections with different charging rates. The battery management system segments the charging profile into distinct phases (first constant current section with higher rate, second constant current section with standard rate, and third constant current section with lower rate), allowing accurate prediction of charging time for each segment while maintaining overall system manageability.
Solution Approach 2:
The charging rate is made dynamic rather than fixed. The battery management system adjusts the charging rate based on real-time battery state (temperature, charge level) by transitioning between different constant current sections. This dynamic adjustment enables accurate charging time prediction while adapting to changing battery conditions.
2Loss of time
If a higher charging rate is used throughout, then the total charging time is reduced, but the battery temperature may exceed operation limits
Solution Approach 1:
The charging process uses periodic alternation between different charging rates. The battery management system periodically switches between the first constant current section (higher rate) and subsequent sections (standard or lower rates) based on temperature monitoring. This periodic variation allows the battery to cool between high-rate charging phases, preventing temperature exceedance while maintaining overall fast charging capability.
Solution Approach 2:
The charging rate parameter is changed based on temperature conditions. When temperature approaches operation limits, the system transitions from the first constant current section (higher rate) to subsequent sections (standard or lower rates). This parameter change dynamically adjusts the charging process to maintain temperature within safe limits while minimizing total charging time.
3Productivity
If multiple constant current sections with different rates are used, then charging time can be optimized and predicted, but the control system becomes more complex
Solution Approach 1:
The battery management system performs preliminary calculation of the charging profile before charging begins. It pre-determines the distribution of charging amounts across the first, second, and third constant current sections based on battery capacity and desired charging time. This preliminary action simplifies real-time control by establishing a predetermined charging schedule that optimizes charging efficiency while maintaining manageable system complexity.
Solution Approach 2:
The system uses feedback from battery state monitoring (temperature, charge level) to control transitions between different constant current sections. The battery management system continuously monitors battery conditions and uses this feedback to determine when to switch between charging rates, enabling optimized charging efficiency while keeping control logic based on clear, measurable parameters.
Data Source
AI summary
There is disclosed a battery charging device of a construction machine including a power distribution device that distributes electric energy stored in a battery pack to loads inside a construction machine and electrically connects or disconnects a charger for charging the battery pack to or from the battery pack; and a battery management system that electrically connects the charger to the battery pack by controlling the power distribution device and calculates a charging profile for charging the battery pack, and the charging profile may include a first charging section and a second charging section, the first charging section may include a second constant current charging section in which the battery pack is charged at a standard charging rate, and a first constant current charging section in which the battery pack is charged at a higher charging rate than the standard charging rate, and the second charging section may include a plurality of constant current charging sections in which the battery pack is charged at a constant charging rate for each charging section.