Integrated Battery Charging Module for Forklift Lead Acid Batteries
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Solution Overview
Problem
Existing lead acid batteries for forklift trucks face challenges in efficiently transmitting charge and discharge history data to wall-mounted chargers, limiting the optimization of charging profiles and requiring batteries to be taken to specific charging rooms.
Innovation Solution
Integration of a battery charging module with a control unit, monitor, and interlock relay in the lead acid battery, allowing for data analysis and control of charging profiles, enabling charging at any suitable mains supply and preventing motive power during charging, along with wireless communication for status notifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery is taken to dedicated charging rooms with wall-mounted chargers, then the charging process can be optimized using monitoring devices, but the operation becomes inconvenient and requires specific locations
Solution Approach 1:
The patent combines the battery charger, battery monitor, and control unit into an integrated battery charging module that is part of the battery itself. This merging eliminates the need for separate wall-mounted chargers in dedicated charging rooms, allowing the battery to be charged anywhere with a mains power supply while maintaining monitoring and optimization capabilities.
Solution Approach 2:
The battery charging module is self-contained with its own control unit that automatically receives data from the battery monitor and determines optimal charging profiles without external intervention. The system serves itself by internally processing battery status data and controlling the charging process, eliminating the need for external charging room infrastructure.
2Adaptability or versatility
If the battery can be charged at any power point, then charging flexibility is improved, but the risk of battery damage from unauthorized or improper charging increases
Solution Approach 1:
The battery monitor continuously provides feedback data about the battery's charge and discharge history to the control unit. This feedback mechanism allows the control unit to make real-time decisions about charging parameters and to detect abnormal conditions, ensuring the battery is protected even when charged at various locations outside dedicated charging rooms.
Solution Approach 2:
The control unit dynamically adjusts charging profiles based on real-time battery status data received from the battery monitor. This dynamic control allows the system to adapt to different charging conditions and locations while maintaining battery safety, enabling the battery to be charged anywhere with mains power without compromising protection.
3Ease of operation
If the battery provides motive power during charging, then operational flexibility is maintained, but the battery and forklift truck may be damaged
Solution Approach 1:
The interlock relay is configured to prevent the battery from providing motive power during charging as a preliminary protective measure. This anti-action mechanism is built into the system architecture to proactively prevent the harmful condition of simultaneous charging and power delivery, protecting both the battery and forklift truck before damage can occur.
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 convenient and optimized charging of lead acid batteries at any power point, preventing damage from over-discharge or overheating, and providing flexible charging solutions without the need for dedicated charging rooms.
Implementation Method 1
the battery monitor arranged to monitor the charge and/or discharge of the battery
Implementation Method 2
a battery charger arranged to supply current and voltage to the battery
Data Source
Figure 1~2
AI summary
The present invention concerns battery apparatus (10), more particularly batteries for providing power to electric vehicles such as fork lift trucks. The invention includes a battery comprising a battery charging module (12). The battery charging module (12) comprises a battery charger (14) arranged to supply current and voltage to the battery. The battery further includes a battery monitor (16), the battery monitor (16) arranged to monitor the charge and/or discharge of the battery. The battery charging module (12) is preferably an integrated part of the battery.