Battery String Segmentation for Industrial Vehicle Fault Isolation
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Solution Overview
Problem
Industrial vehicles, particularly those used in mining, face risks due to high voltage battery systems that can lead to engine malfunctions and immobilization when components are damaged by falling rocks or other hazards, necessitating a system to monitor and manage battery failures to ensure continued operation.
Innovation Solution
A battery system with multiple strings of modules connected in series and parallel, along with contactors and controllers to monitor and disconnect faulty strings, allowing the vehicle to operate on remaining power and prevent further damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high voltage battery systems are used to power industrial vehicles, then power output and torque are improved, but reliability and safety deteriorate due to increased risk of engine malfunctions and battery failures
Solution Approach 1:
The battery system is divided into multiple independent strings (first string, second string, third string) with each string containing multiple modules. This segmentation allows the vehicle to operate on remaining functional strings when one string fails, maintaining reliability while providing high power output. The controller can selectively activate different strings based on operational needs and system status.
Solution Approach 2:
The system includes precharge circuits with precharge resistors and precharge contactors that are activated before main contactors close. This preliminary action prevents inrush current damage to the battery system and contactors, addressing potential failure modes before they occur. The precharge mechanism ensures safe energization of the high voltage system.
2Reliability
If battery systems are monitored to detect failures, then reliability is improved, but device complexity increases due to additional monitoring systems and devices
Solution Approach 1:
The controller performs multiple functions: it monitors battery parameters (voltage, current, temperature), manages contactor activation sequences, controls precharge circuits, and implements failure detection and response. This multi-functionality reduces the need for separate dedicated monitoring devices, maintaining reliability while managing system complexity through integration.
3Reliability
If multiple contactors are used to manage battery strings, then reliability is improved through failure isolation, but device complexity increases due to additional contactors and control circuits
Solution Approach 1:
The battery system uses multiple contactors (first contactor, second contactor, third contactor, fourth contactor) to isolate and manage different battery strings. When a failure is detected in one string, the controller can open the relevant contactors to isolate that string while keeping other strings operational. This segmentation enables failure isolation and maintains system reliability.
Solution Approach 2:
The controller acts as an intermediary that manages the complex interactions between multiple contactors, precharge circuits, and battery strings. It coordinates the activation and deactivation sequences, monitors system status, and makes real-time decisions about which contactors should be closed or opened based on operational requirements and detected failures.
4Power
If battery modules are connected in series to increase voltage, then power output is improved, but safety deteriorates due to higher voltage risks and increased impact from component damage
Solution Approach 1:
The high voltage battery system is segmented into multiple independent strings that can be individually managed. When operating at high voltages, a failure in one string can be isolated by opening contactors, preventing the high voltage risk from affecting the entire system. This segmentation reduces the harmful effects of high voltage while maintaining the power output benefits.
Solution Approach 2:
The system includes protective measures such as precharge circuits that prevent inrush current damage, and contactor systems that can quickly isolate faulty sections. These cushioning measures are in place before failures occur, protecting the high voltage system from damage and reducing safety risks associated with high voltage operation.
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
The system ensures safe and continued operation of industrial vehicles by monitoring battery parameters, disconnecting faulty strings, and distributing power across multiple modules, reducing the risk of immobilization and enhancing safety in hazardous environments.
Implementation Method 1
a battery system including a first string of battery modules including at least two battery modules connected in series
Data Source
AI summary
In some aspects, a method of monitoring a battery system of an industrial vehicle is disclosed. The battery system may include a first string of battery modules including at least two battery modules connected in series; a first contactor connected to a positive end of the first string of battery modules, a second contactor connector to a negative end of the first string of battery modules; a third contactor connected to the first contactor; a fourth contactor connected to the second contactor; and one or more controllers configured to monitor the first contactor and the second contactor. The method may include receiving, at the one or more controllers, an indication of a failure of one of the first contactor and the second contactor; and opening, via the one or more controllers, at least one of the third contactor or the fourth contactor.