Battery Cooling Control for On-Demand Work Machine Conditioning
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Solution Overview
Problem
Battery-powered work machines face inefficiencies in thermal management due to automatic, on-demand cooling that occurs only during operation, leading to potential overheating, reduced runtime, and increased energy consumption, as well as unnecessary cooling at low temperatures.
Innovation Solution
A work machine with a cooling device that includes a fan system controlled by temperature sensors and a control unit, allowing for demand-driven cooling and temperature conditioning, enabling the fan to be switched on or off and adjusted based on predefined temperature limits, and considering the state of the battery and other components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a fan wheel is provided on the electric motor to permanently generate a cooling air flow during operation, then the battery and converter are cooled during operation, but the components are cooled even when not yet at critical temperature and energy is consumed unnecessarily
Solution Approach 1:
The cooling system transitions from a static permanent cooling approach to a dynamic on-demand cooling approach. The control device activates the cooling air flow only when temperature sensors detect that components have reached critical temperature thresholds, and deactivates it when temperatures are within acceptable ranges, optimizing energy consumption while maintaining effective thermal management
Solution Approach 2:
Temperature sensors continuously monitor the thermal state of the battery and converter, providing feedback to the control device. Based on this feedback, the control device intelligently activates or deactivates the cooling air flow, creating a closed-loop control system that responds to actual thermal conditions rather than operating continuously
2Use of energy by moving object
If cooling occurs exclusively during operation of the drive motor, then the fan is not running constantly, but preconditioning or postconditioning or temperature control of the battery is not possible
Solution Approach 1:
The control device is configured to activate the cooling air flow in advance before the drive motor is started if temperature sensors detect that the battery has already reached critical temperature. This preliminary cooling action prevents the battery from overheating during upcoming operation, extending runtime and improving reliability without requiring constant fan operation
3Ease of operation
If the battery is activated by a pushbutton or switch before starting up the machine, then the operator can switch on the electric motor within a specified period, but the battery must be deactivated again after switching off the electric motor
Solution Approach 1:
The control device automatically manages the battery activation state based on the operational state of the drive motor. When the motor is switched off, the control device automatically deactivates the battery without requiring operator intervention. This self-service approach eliminates the need for manual pushbutton operations and reduces time loss while maintaining safety
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 preventing overheating, extending battery runtime, reducing energy consumption, and maintaining components within optimal operating temperatures, thereby improving the reliability and efficiency of battery-powered work machines.
Implementation Method 1
at least one fan device (15) for generating a cooling air flow (16) which can be directed over the energy storage device (10)
Data Source
AI summary
A work machine includes a working device for generating a working motion; an electric motor for driving the working device; an electric energy storage device for supplying the electric motor with electric current; and a cooling device for cooling the energy storage device. The cooling device comprises at least one fan device for generating a cooling air flow which can be directed over the energy storage device. At least one temperature sensor is provided for detecting a temperature, and a control device is provided for controlling the fan device as a function of the temperature detected by the temperature sensor.