Dual Control Loop Battery Charging via Generator Controller
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Solution Overview
Problem
Existing generator-based battery charging systems face inefficiencies and potential damage to battery modules due to overlooked environmental or electrical conditions, especially when charging mixed battery types, leading to increased costs, complexity, and risk of component failure.
Innovation Solution
A generator-based battery charging system utilizing a controller with dual control loops to analyze sensor signals for temperature, voltage, and current, adjusting the charging current to prevent overcharging and maintaining the alternator voltage above the battery's open circuit voltage, thereby ensuring safe and efficient charging without a separate charger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional one-step or two-step charging processes are used for Li-ion batteries, then the charging process is simple to implement, but the system may fail to efficiently charge batteries or cause damage due to overlooked environmental or electrical conditions
Solution Approach 1:
The patent implements a dual control loop system with inner current control loop and outer voltage control loop that continuously monitor and adjust charging parameters. The controller receives feedback from voltage and current sensors to dynamically regulate the generator output, ensuring the battery charging process remains within safe operating boundaries while maximizing charging efficiency.
Solution Approach 2:
The system dynamically changes charging parameters (current and voltage) based on real-time battery conditions and generator output. The control algorithm adjusts the charging current profile and voltage setpoints according to battery state of charge, temperature, and generator capabilities, transitioning between different charging phases automatically.
2Measurement precision
If a specialized battery charger is used to charge mixed battery types, then the charging accuracy is improved, but the system complexity, cost, and weight increase
Solution Approach 1:
The patent makes the generator controller perform multiple functions: it controls the generator output voltage and current, monitors battery charging parameters, implements dual control loops, and adapts to different battery types and conditions. This eliminates the need for a separate specialized battery charger while maintaining charging accuracy through integrated control functionality.
Solution Approach 2:
The system merges the battery charging control functionality into the existing generator controller, combining the roles of voltage regulation, current control, and battery management into a single integrated control unit. This consolidation reduces system complexity by eliminating redundant components while preserving charging precision through sophisticated control algorithms.
3Reliability
If a separate battery charger is used to ensure safe charging, then the battery protection is improved, but the system complexity and cost increase
Solution Approach 1:
The generator controller is designed to perform multiple functions including voltage regulation, current control, and battery protection. It monitors battery voltage, current, and temperature while implementing dual control loops to ensure safe charging operation, thereby providing battery protection without requiring a separate dedicated charger.
Solution Approach 2:
The patent combines battery protection functionality with the generator control system by integrating voltage and current control loops that monitor and regulate charging parameters. This merger provides comprehensive battery protection while reducing system complexity by eliminating the need for separate protection circuits and components.
Data Source
AI summary
A system for generator-based charging of a battery module may include the battery module, a sensor located adjacent the battery module, a generator controller comprising a processor and a non-transitory memory device storing instructions. The battery modules include one or more battery types, such as lithium ion batteries. The generator controller analyzes one or more sensor signals received from the sensor, the signals associated with battery conditions including temperature, a current, a voltage, a state of charge, a state of health and the like. The generator controller calculates a generator current value for use in charging the battery module. Next, the generator controller may generate a control signal comprising a command that may cause the generator to provide a charging current having the current value. The control signal is generated using a first control loop associated with a battery voltage and a second control loop associated with a battery current.