Battery Interrupter System for Heavy Machinery Hazard Isolation
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Solution Overview
Problem
Current monitoring and protection systems for heavy machinery and vehicles do not provide an automatic protocol to prevent catastrophic failures due to hazardous conditions such as fire or excessive heat, and aftermarket retrofit systems can void warranties and are prone to failures and operator manipulation.
Innovation Solution
A battery interrupter system that includes a programmable logic controller, contactors, and sensors to isolate the battery from the electrical system when hazardous conditions are detected, using a timer to conserve battery life and prevent fire damage, and can be integrated with existing machinery systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery interrupter system is implemented to automatically isolate the battery during hazardous conditions, then protection reliability is improved, but device complexity increases
Solution Approach 1:
The battery interrupter system divides the electrical system into separable components: a battery isolation switch that can disconnect the battery from the electrical system, temperature sensors positioned at critical locations, and a control module. This segmentation allows the system to isolate only the necessary components during hazardous conditions rather than shutting down the entire system, improving protection reliability while managing complexity through modular design.
Solution Approach 2:
The system performs preliminary actions by pre-positioning temperature sensors near the battery and other critical components, and pre-programming the control module with threshold values for automatic activation. When hazardous conditions are detected, the system immediately activates the battery isolation switch without requiring operator intervention. This preliminary preparation ensures rapid response to hazards while maintaining system simplicity through pre-configured automatic protection.
2Measurement precision
If continuous monitoring of operating parameters is implemented, then detection precision is improved, but energy consumption increases
Solution Approach 1:
The temperature monitoring system uses periodic sampling rather than continuous monitoring. The control module checks temperature readings at predetermined intervals and compares them against threshold values. This periodic action maintains adequate detection precision for identifying hazardous conditions while significantly reducing energy consumption compared to continuous monitoring, allowing the system to operate efficiently during extended periods between checks.
Data Source
AI summary
A battery interrupter system including an electrical motor for a machine, at least one battery which powers an electrical system of a machine, a programmable logic controller electrically connected to the electrical system and an ignition electrically connected to the programmable logic controller. The battery interrupter system also includes a button, which initiates the battery interrupter system, is connected to the programmable logic controller, at least one contactor electrically connected to the at least one battery and the programmable logic controller, wherein the programmable logic controller is configured to sends a signal to the at least one contactor to latch-in the contactor and enable an electrical connection between the at least one battery and the electrical system of the machine, and a detection sensor electrically connected to the programmable logic controller, wherein the detection sensor identifies operating conditions of the electrical system.