Dual High-Voltage Battery Control for Faster Vehicle Battery Swaps
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Solution Overview
Problem
The replacement of high-voltage batteries in heavy-duty vehicles, such as trucks and construction equipment, is time-consuming due to the need for dedicated operators, especially when multiple vehicles require simultaneous battery replacement, leading to increased lead times at work sites.
Innovation Solution
A battery arrangement comprising a primary and secondary high-voltage battery connected to an electric traction motor, with a control unit that manages power transfer between them, allowing the secondary battery to be depleted and the primary battery to be charged before replacement, enabling the use of an externally charged battery to maintain optimal power levels and reduce replacement time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If battery replacement is performed manually with dedicated operators, then battery replacement can be executed, but the replacement process becomes time-consuming and increases lead time
Solution Approach 1:
The system enables self-service battery replacement through automated detection and management. The control unit automatically detects battery status, manages power transfer between batteries, and coordinates replacement timing without requiring manual operator intervention for decision-making, reducing both operational complexity and time loss
Solution Approach 2:
The system performs preliminary actions by proactively managing battery charge levels before replacement is needed. The control unit transfers power from the secondary battery to the primary battery in advance, ensuring the primary battery is fully charged and ready for immediate operation upon battery swap, thereby eliminating waiting time
2Productivity
If multiple vehicles require simultaneous battery replacement, then fleet maintenance can be performed, but the lead time increases significantly
Solution Approach 1:
The system performs preliminary charging actions before replacement events. By continuously managing power transfer between primary and secondary batteries, the system ensures batteries are optimally charged and ready for immediate swap, enabling multiple vehicles to undergo replacement simultaneously without queueing delays
Solution Approach 2:
The control unit continuously monitors battery status, charge levels, and vehicle operational needs, using this feedback to optimize replacement timing and power management strategies across the fleet, thereby improving overall fleet maintenance productivity while minimizing total lead time
3Use of energy by moving object
If the secondary battery is depleted before replacement, then power optimization is achieved, but the primary battery needs to be charged in advance
Solution Approach 1:
The system merges the functions of two batteries into a coordinated power management system. The control unit manages power transfer between the primary and secondary batteries, allowing them to work together as a unified energy system that optimizes overall power availability and usage efficiency
Solution Approach 2:
The system performs preliminary power transfer from the secondary battery to the primary battery before the secondary battery is depleted and before replacement occurs. This preliminary charging action ensures the primary battery is fully charged and ready for extended operation, optimizing power utilization while preparing for efficient battery swap
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
This solution improves the charge level of the primary battery before replacement, ensures efficient battery depletion, and reduces lead times by allowing the vehicle to be driven to a replacement site when an externally charged battery is available, optimizing energy management and extending battery lifespan.
Implementation Method 1
the primary and second batteries are electrically connected to each other for feeding electric power there between
Data Source
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AI summary
The present inventive concept relates to a battery arrangement for a vehicle, the battery arrangement comprising a primary high-voltage battery, a secondary high-voltage battery, wherein the primary and second batteries are electrically connected to each other for feeding electric power there between, and a control unit comprising a processor device coupled to the primary and secondary batteries, the processor device being configured to receive data indicative of an upcoming battery replacement event, at which battery replacement event the secondary high-voltage battery will be replaced with an externally charged high-voltage battery, and control one of the primary high-voltage battery and the secondary high-voltage battery to feed electric power to the other one of the primary high-voltage battery and the secondary high-voltage battery prior to replacement of the secondary high-voltage battery.