Rechargeable Battery Power System for Construction Equipment
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Solution Overview
Problem
Existing battery designs are not universally applicable and lack versatility to power a wide range of devices from light towers to heavy construction equipment, requiring improved designs for increased applicability and efficiency.
Innovation Solution
A rechargeable battery power system featuring a self-contained lithium-ion battery assembly with multiple module banks, a battery management system, and a variable frequency motor driver, which can be integrated into various equipment, including excavators and light towers, converting DC power to AC for efficient energy use without active cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing battery designs are used, then they can power specific devices, but they lack universal applicability to power diverse equipment from light towers to heavy construction equipment
Solution Approach 1:
The battery assembly is designed with a standardized housing structure, terminal configuration, and module bank arrangement that enables it to power diverse equipment including light towers, construction equipment, and other devices requiring electrical power. The housing includes standardized features such as service disconnects, current sensors, and mounting interfaces that facilitate universal application across different device types.
2Device complexity
If a self-contained battery design is used, then cooling systems are eliminated, but the battery must maintain thermal management without active cooling
Solution Approach 1:
The battery assembly incorporates passive thermal management through its housing design, which includes thermally conductive materials and structural features that dissipate heat without requiring active cooling systems. The housing structure itself serves as a thermal management solution, eliminating the need for separate cooling components while maintaining safe operating temperatures.
3Power
If multiple module banks are used, then power output and run time are increased, but the battery assembly becomes more complex
Solution Approach 1:
The battery assembly is divided into multiple module banks, each containing several modules that can be independently configured. This segmentation allows the system to provide high power output through parallel connections while maintaining manageable complexity through standardized module designs. The housing structure organizes these modules in a systematic arrangement with dedicated separator support plates and structural members for each bank.
Solution Approach 2:
Multiple module banks are combined within a single integrated housing structure that provides unified support, protection, and thermal management. The housing merges the functionality of multiple separate battery units into one cohesive assembly, reducing overall system complexity while maintaining the power benefits of multiple banks through standardized connection interfaces and shared structural components.
4Power
If the battery is designed for heavy equipment applications, then power density is increased, but the housing and structural components must be more robust
Solution Approach 1:
The battery housing employs composite construction combining metal components for structural strength and aluminum or aluminum alloy materials for lighter structural members. This composite approach provides the robustness needed for heavy equipment applications while minimizing unnecessary weight. The housing integrates different materials optimized for their specific functions: strength where required and weight reduction where possible.
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 provides a clean, quiet, and efficient power source capable of powering diverse applications, offering long run times and adaptability, reducing noise and environmental impact, while eliminating the need for fuels and toxic emissions.
Implementation Method 1
The battery is a multiple use battery because it may be used in a plurality of different applications ranging from a stand-alone power source to a power source for powering equipment, lights and virtually any other machine that has a need for electrical power
Implementation Method 2
converting DC power to AC for efficient energy use
Data Source
AI summary
Conventional internal combustion engine technology has been around for decades and historically has been the primary power source for virtually all industrial equipment. It relies on carbon-based fuels, is loud, polluting, and the machines it powers are expensive to operate and maintain. A self-contained, rechargeable battery system is provided that possesses superior power than comparable diesel and gas engines. The rechargeable battery power system generates zero emissions, is virtually maintenance free, is quiet, and recharges overnight via a standard electrical outlet. The rechargeable battery power system can be installed in new and used construction equipment (light towers, excavators, generators) and may be used wherever a source of power is required, for example, in vans and boats, and in supplemental power systems including smart grid applications. It can be safely used indoors, in neighborhoods and other locations sensitive to the side effects of internal combustion engines.