Battery Cooling Control for Demand-Based Working Machines
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Solution Overview
Problem
Battery-operated work machines face inefficiencies in thermal management due to non-demand-based cooling, leading to premature shutdowns and potential damage from excessive temperatures, as well as energy wastage from constant fan operation, especially at low outside temperatures.
Innovation Solution
A work machine with a cooling system that includes a fan device controlled by a temperature sensor and control unit, allowing for demand-based cooling and temperature conditioning, enabling the fan to be switched on/off and speed regulated based on temperature limits and operational states, thereby pre- and post-conditioning the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the fan device runs constantly to cool the battery and converter, then the components are cooled, but energy consumption increases and components are cooled even when not necessary
Solution Approach 1:
The fan device operates dynamically based on real-time temperature conditions. The control device activates the fan only when temperature sensors detect that the battery or converter exceeds predetermined temperature thresholds, and deactivates it when temperatures are within acceptable ranges. This dynamic operation adapts the cooling system to actual thermal conditions, avoiding unnecessary energy consumption while maintaining component temperatures within safe limits.
Solution Approach 2:
The cooling system incorporates temperature sensors that continuously monitor the thermal state of the battery and converter. These sensors provide feedback to the control device, which automatically adjusts fan operation accordingly. When temperature feedback indicates overheating, the fan activates; when feedback shows acceptable temperatures, the fan deactivates. This closed-loop feedback mechanism ensures cooling is applied only when necessary, optimizing energy efficiency.
2Temperature
If the fan device is activated permanently during motor operation, then cooling is ensured, but the battery operates below optimal temperature for extended periods at low outside temperatures
Solution Approach 1:
The cooling system dynamically adjusts fan operation based on actual temperature needs rather than running continuously. At low outside temperatures, the temperature sensors detect that the battery and converter remain within acceptable temperature ranges, so the control device keeps the fan deactivated, allowing the machine to operate for extended periods without unnecessary cooling intervention. The fan activates only when temperature thresholds are exceeded.
Solution Approach 2:
Temperature feedback from sensors continuously monitors the thermal state of components. When feedback indicates temperatures are within optimal ranges (even at low outside temperatures), the control device maintains fan deactivation, extending operational time. The system responds to feedback by activating cooling only when temperature thresholds indicate overheating conditions.
3Speed
If the battery is activated with a predetermined time limit for motor start-up, then the system responds quickly, but the battery may overheat from previous charging/discharging before conditioning can occur
Solution Approach 1:
The control device performs preliminary thermal assessment immediately upon battery activation. Temperature sensors check the battery and converter temperatures before the predetermined time limit expires. If temperatures are within acceptable ranges, the system permits immediate motor start-up. If temperatures exceed thresholds, the control device activates the fan for pre-cooling during the standby period, ensuring components are conditioned before full operation begins, thus preventing overheating while maintaining quick response.
Solution Approach 2:
Temperature feedback is evaluated immediately upon battery activation. The control device uses this feedback to determine whether pre-cooling is necessary before motor start-up. If feedback shows elevated temperatures, the fan activates during the predetermined time window to cool components. If feedback shows acceptable temperatures, the fan remains deactivated and the motor can start immediately, ensuring rapid response while preventing overheating.
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 enhances thermal management by extending the battery's operational time, preventing damage, and reducing energy consumption by ensuring components operate within optimal temperature ranges, thus improving the machine's efficiency and lifespan.
Implementation Method 1
at least one temperature sensor is provided for detecting a temperature
Implementation Method 2
a cooling device for cooling the energy storage, the cooling device having at least one fan device, for generating a cooling air flow that can be guided via the energy storage
Data Source
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AI summary
A working machine is described, comprising a working device for generating a working movement; an electric motor (5) for driving the working device; an electrical energy storage device (10) for supplying the electric motor with electric current; and a cooling device for cooling the energy storage device (10); wherein the cooling device has at least one fan device (15) for generating a cooling airflow (16) that can be directed over the energy storage device (10); wherein at least one temperature sensor (26) is provided for detecting a temperature; and wherein a control device (25) is provided for controlling the fan device (15) depending on the temperature detected by the temperature sensor (26).