Engine-Driven Portable Battery Charger with Anti-Spark Control
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Solution Overview
Problem
Existing portable battery chargers for lead-acid batteries in remote locations require access to AC power, limiting their use in environments without electrical outlets, and are inefficient in rapidly recharging large banks of batteries.
Innovation Solution
A portable battery charger powered by a small internal combustion engine, utilizing a high-efficiency permanent magnet alternator and a wheeled cart for portability, with an anti-spark control box, ammeter, and voltmeter for safe and efficient charging, allowing adjustment of voltage and current output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If AC-powered battery chargers are used, then portability is improved, but availability is limited to locations with AC outlets
Solution Approach 1:
The invention extracts the alternator from the automotive context and places it in a portable charger unit with its own engine, removing the dependency on external AC power infrastructure while maintaining the core battery charging function
Solution Approach 2:
The invention replaces the electrical AC power input system with a mechanical internal combustion engine system that drives an alternator, enabling operation in locations without electrical infrastructure
2Productivity
If traditional alternators are used, then charging capability is provided, but charging speed is slow for large battery banks
Solution Approach 1:
The invention changes the operational parameters by using an engine-driven alternator system that can deliver higher current output compared to traditional AC chargers, enabling rapid charging of large battery banks in 2-4 hours
Solution Approach 2:
The invention introduces dynamic control through engine throttle adjustment that allows variation of voltage and current output to optimize charging speed for different battery bank configurations and states of charge
3Power
If engine-driven alternators are used, then charging power is increased, but device complexity increases
Solution Approach 1:
The invention merges the engine, alternator, control systems, and transport components into a single integrated portable unit, managing the complexity through unified design rather than separate systems
Solution Approach 2:
The invention creates a multi-functional device that combines rapid battery charging capability with portable transport features, making it suitable for various applications from automotive to marine to remote locations
4Loss of time
If rapid charging is implemented, then charging time is reduced, but safety risks from sparks increase
Solution Approach 1:
The invention implements preliminary safety actions by providing anti-spark clamps and controlled connection procedures that prevent hazardous sparks before they can occur during the rapid charging process
Solution Approach 2:
The invention introduces intermediary safety components such as anti-spark clamps and controlled switching mechanisms that mediate between the high-power charging system and the battery connections, preventing direct spark generation
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
Enables rapid charging of multiple batteries in less than 2-4 hours without AC power, enhancing portability and safety while utilizing recent advances in generator efficiency.
Implementation Method 1
a high-efficiency permanent magnet alternator/generator connected through a cut-off switch to battery clamps
Data Source
AI summary
A portable battery charger that is powered by a gasoline, diesel, or propane engine. The portable device incorporates a recoil or electric starter and an engine throttle lever that can be used to vary the RPM of the engine and therefore the voltage/current output of the charger. The charger uses a permanent magnet alternator equipped with a belt tension adjustor arm and a heavy duty diode rectifier. The components of the charger (the engine and the alternator) are positioned on a wheeled, heavy-gauge steel, roll around cart that makes the charger easily portable. The two-wheeled cart includes an extended handle, allowing the user to move and steer the charger into position for use. Positioned on this handle is a control box with an anti-spark keyed switch that blocks any charging current from traveling through the charging cables until the switch is thrown. This control facilitates the safe hook-up of the charging clamps while the charger (engine) is running. The charger includes heavy duty cables between the alternator and the anti-spark control box, and additionally out from the control box to insulated clamps that are used to connect to the batteries. The control box additionally includes an ammeter and a voltmeter to indicate the charging current and voltage. The portable charger structured in this manner can be used to charge a non-specific number of batteries in parallel, typically in less than 2-4 hours depending on the size and state of the existing battery charge. The charger may also be used in the process of equalizing a bank of batteries to facilitate a reduction in stratification and sulfation.