Industrial Battery Switching Isolation for Heater Fault Detection
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Solution Overview
Problem
Existing industrial battery designs for material handling vehicles lack efficient temperature management and fault detection mechanisms, leading to unnecessary wear on switching devices and potential safety risks.
Innovation Solution
A battery design incorporating isolated switching devices controlled by a controller that selectively opens and closes based on temperature data and fault detection, reducing wear and enhancing safety by sequencing the operation of switching devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single switching device is used to control power to the heater, then the control structure is simple, but the switching device experiences unnecessary wear and potential failure when both temperature management and fault detection are required
Solution Approach 1:
The single switching device is segmented into two separate switching devices: a first switching device that controls power to the heater, and a second switching device that controls power to the temperature sensor. This segmentation allows independent control of heating and sensing functions, preventing unnecessary wear on a single device while maintaining reliable operation for both temperature management and fault detection.
2Reliability
If the switching device is opened frequently for fault detection, then safety is improved, but wear on the switching device increases
Solution Approach 1:
By separating the control functions into two switching devices, the system can open the second switching device for fault detection without necessarily opening the first switching device. This reduces the frequency of operations on the primary power control device, extending its service life while maintaining safety through the second device.
Solution Approach 2:
The second switching device acts as an intermediary for fault detection purposes, allowing the system to monitor and detect faults without requiring the primary first switching device to open frequently. This intermediary device absorbs the wear from frequent operational changes while the first device maintains stable power control.
3Reliability
If temperature management is implemented, then battery safety is improved, but the system complexity and energy consumption increase
Solution Approach 1:
The temperature management system is segmented into separate control functions using two switching devices. This allows the controller to manage heater power and sensor power independently, enabling precise energy management where power is supplied only when needed for heating or sensing, rather than continuously, thus improving safety while optimizing energy consumption.
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 solution provides improved temperature management and fault detection, reducing wear on switching devices and enhancing the reliability and safety of industrial batteries.
Implementation Method 1
a heater to provide heat to the battery cell
Implementation Method 2
a temperature sensor to monitor a temperature of the battery cell
Data Source
AI summary
An industrial battery design for use in a material handling vehicle. The battery includes a battery cell, a heater to provide heat to the battery cell, a temperature sensor to monitor a temperature of the battery cell, a first switching device through which power for the heater is routed, a second switching device through which power for the heater is not routed, and a controller. The controller includes circuitry configured to receive temperature data indicative of the temperature of the battery cell from the temperature sensor and to open the first switching device without opening the second switching device based on the temperature data received from the temperature sensor.