Battery Equalizer Saturation 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 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
A method and system that monitors the equalizing current and reduces the 12V current supplied to the load when the equalizing current is saturated, using an electrical control unit with a microcontroller to manage the battery equalizer and alternator to maintain balanced charging and discharging of the batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery equalizer is used to balance charging and discharging of batteries, then battery life is improved, but the equalizer current may become saturated causing the system to fail to prevent overcharging and undercharging
Solution Approach 1:
The control method continuously monitors the equalizer current level and uses this feedback to detect saturation conditions. When saturation is detected, the system automatically adjusts the 12V current supplied to the load, creating a closed-loop control system that prevents overcharging and undercharging, thereby resolving the reliability issue caused by equalizer saturation
Solution Approach 2:
The system dynamically adjusts the 12V current supplied to the load based on the real-time status of the equalizer current. By making the current supply adaptive and variable rather than fixed, the system can respond to saturation conditions and maintain proper battery charging balance, preventing the harmful effects of equalizer saturation
2Productivity
If the lower battery supplies power to both 12V and 24V loads, then the electrical system can operate with fewer components, but the lower battery discharges faster causing charge imbalance between batteries
Solution Approach 1:
The system monitors the charge status of both batteries and the equalizer current level to detect when charge imbalance occurs. This feedback mechanism enables the control unit to identify when the lower battery is discharging excessively and trigger appropriate responses to restore charge balance
Solution Approach 2:
The system takes preliminary action by monitoring equalizer current levels and detecting saturation conditions before severe charge imbalance occurs. By early detection and intervention, the system prevents the lower battery from being over-discharged and the upper battery from being under-charged, maintaining charge balance proactively
Data Source
AI summary
Provided is 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.