Battery Equalizer Overload Control in Dual-Voltage Systems
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Solution Overview
Problem
In dual voltage vehicle electrical systems, the battery equalizer may saturate, leading to unequal charging and discharging of series-connected batteries, causing overcharging of the upper battery and undercharging of the lower battery, which reduces battery life and can result in system failure.
Innovation Solution
An equalizer management system that monitors the equalizing current and takes remedial actions such as reducing 12V current demand, alerting users, or automatically starting the engine to prevent equalizer saturation, thereby maintaining balanced battery states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the alternator charges both batteries in series, then charging simplicity is improved, but the lower battery may become saturated while the upper battery remains undercharged
Solution Approach 1:
The battery equalizer acts as an intermediary device that redistributes charging current between the series-connected batteries. It intercepts current from the alternator and redirects it to the lower battery when needed, maintaining charge equality without complicating the overall series charging architecture
Solution Approach 2:
The charging function is segmented into two paths: the main alternator charging path for both batteries, and a secondary equalizer path that selectively charges the lower battery. This segmentation allows independent control of charging current distribution while maintaining system simplicity
2Duration of action of stationary object
If the equalizer continuously balances battery charge, then battery life is improved, but system complexity and power loss increase
Solution Approach 1:
The equalizer operates periodically rather than continuously, activating only when charge imbalance is detected and deactivating when batteries are balanced or the lower battery is fully charged. This periodic operation reduces energy losses while maintaining battery life benefits
Solution Approach 2:
The system uses the alternator's existing charging output to power the equalizer function, drawing equalizer current from the alternator's charging current rather than from a separate power source. This self-service approach minimizes additional energy losses
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
Prevents equalizer saturation, ensuring both batteries are maintained at an equal state of charge, reducing the risk of overcharging or undercharging, and extending battery life by managing 12V current supply based on saturation levels and charge imbalances.
Implementation Method 1
the battery equalizer may redirect some of the power coming from the alternator so that the charge voltages being applied across both batteries are equal
Data Source
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AI summary
A method of operating an electrical system including a first battery, a second battery coupled in series with the first battery, and a battery equalizer coupled to the first battery and the second battery and configured to supply an equalizing current to the first battery. The method includes monitoring a level of the equalizing current, determining, based on monitoring of the level of the equalizing current, that the equalizing current is saturated, and reducing a level of current supplied at a positive terminal of the first battery in response to determining that the equalizing current is saturated. The methods may take an action to reduce the demand for current that is supplied by the first battery.