Battery State-of-Charge Control for Longer Li-Ion Pack Life
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Solution Overview
Problem
Lead acid batteries used in material handling devices have short lifecycles, are bulky, unsuitable for fast charging, and pose safety hazards, while lithium-ion batteries offer advantages but require methods to extend their life for increased return on investment.
Innovation Solution
A system that monitors and controls the state of charge of lithium-ion batteries by storing usage data, determining usage thresholds, and adjusting charging states to optimize battery health, along with predictive quantum balancing to balance cell voltages within the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If lithium-ion batteries are charged to maximum capacity to increase energy storage, then the energy storage increases, but the battery life decreases due to accelerated degradation
Solution Approach 1:
The patent implements dynamic state of charge management that adjusts charging parameters in real-time based on battery condition, usage patterns, and environmental factors. The system transitions from static maximum charging to adaptive charging that optimizes the balance between energy storage and battery longevity through continuous monitoring and parameter adjustment.
Solution Approach 2:
The system changes multiple parameters including state of charge thresholds, charging rates, temperature compensation factors, and voltage limits based on battery age, usage history, and current conditions. These parameter adjustments allow the battery to operate in optimal ranges that extend life while maintaining sufficient energy storage capacity.
2Productivity
If battery capacity is increased to reduce charging frequency, then the energy storage increases, but the battery size and weight increase
Solution Approach 1:
The system implements partial charging strategies that charge the battery to optimized levels rather than always to maximum capacity. By charging to appropriate state of charge thresholds based on predicted usage patterns, the system reduces the need for oversized batteries while maintaining adequate energy storage for operational requirements.
Solution Approach 2:
The system performs preliminary analysis of usage patterns, historical data, and operational requirements to pre-determine optimal charging parameters before charging occurs. This predictive approach allows the battery to be sized appropriately for actual needs rather than maximum theoretical requirements, reducing unnecessary weight.
3Speed
If fast charging is implemented to reduce charging time, then the charging speed increases, but the battery overheating and degradation increase
Solution Approach 1:
The system implements periodic charging cycles that alternate between high-rate fast charging phases and lower-rate conditioning phases. This periodic approach allows heat dissipation during transition periods while maintaining overall fast charging performance, preventing thermal accumulation and reducing degradation from continuous high-rate charging.
Solution Approach 2:
The system applies preliminary counter-actions by monitoring temperature, voltage, and current parameters in real-time and preemptively adjusting charging parameters before harmful conditions develop. When thresholds are approached, the system reduces charging rate or pauses charging to prevent overheating and degradation before they occur.
Data Source
AI summary
A method and system for operating a battery system includes storing battery charge usage data for a plurality of days in a memory, obtaining usage data for a current day based on a past corresponding day, comparing the usage data for the current day to a plurality of threshold, when the usage data is less than a first usage threshold, setting an operating state of charge range for the current to a first state of charge range, when the usage data is between the first usage threshold and a second usage threshold, setting the operating state of charge range for the current to a second state of charge range greater than the first state of charge range, when the usage data is greater than the second usage threshold, setting the operating state of charge range for the current to a third state of charge range greater the second state of charge range, and charging and discharging the battery system based on the state of charge range during the current.