Integral Battery Actuator Charging for Explosionproof Backup Power
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Solution Overview
Problem
Existing motor-driven actuator mechanisms, such as valve actuators, rely on external batteries that are not suitable for Explosionproof environments and lack active monitoring, making them unsuitable for normal operation or as a sole power source.
Innovation Solution
A motor-driven actuator device with an integrated battery pack and control module that monitors temperature and charging status, adjusts charging currents, and includes features like over-voltage protection and heating to manage battery health, allowing the battery to be used safely in Explosionproof environments and extending its lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external battery is used for backup power, then the actuator can operate during AC supply failure, but the battery is not suitable for Explosionproof environments and lacks active monitoring
Solution Approach 1:
The patent combines the battery pack with the actuator housing to form an integrated Explosionproof unit. The battery pack is housed within the sealed actuator enclosure, allowing the entire assembly to meet Explosionproof requirements while providing both backup and primary power capability.
Solution Approach 2:
The control module actively monitors the battery pack's charge state and temperature, and automatically manages charging operations. This self-monitoring and self-management capability ensures the battery operates safely within specified parameters without external intervention.
2Loss of time
If charging current is increased to charge the battery faster, then charging time is reduced, but the battery may overheat and its lifespan is reduced
Solution Approach 1:
The control module continuously monitors the battery pack's temperature during charging operations. When the temperature exceeds a predetermined threshold, the control module automatically reduces or terminates the charging current, preventing overheating and extending battery lifespan.
Solution Approach 2:
The charging current is dynamically adjusted based on real-time temperature conditions. The system transitions from high-current fast charging to reduced-current safe charging when temperature thresholds are exceeded, optimizing both charging speed and battery longevity.
3Reliability
If the battery pack is made integral to the actuator, then Explosionproof capability is achieved, but the device complexity increases
Solution Approach 1:
The battery pack is integrated within the actuator housing, combining power supply and actuator functions into a single Explosionproof unit. This integration eliminates the need for separate external battery installations and ensures the entire system meets Explosionproof requirements.
Solution Approach 2:
The actuator housing serves multiple functions: it provides structural support for the actuator mechanism, houses the battery pack, and acts as the Explosionproof enclosure. This multi-functionality reduces overall system complexity despite the integration.
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 safe and efficient operation of motor-driven actuators in Explosionproof environments by actively managing battery health, ensuring reliable power supply and extending battery life, while preventing overheating and undercharging.
Implementation Method 1
at least one temperature sensing device associated with said battery pack, the control module being further configured, during charging of the battery pack to: receive from said at least one temperature sensing device, data representative of a measured temperature associated with said battery pack
Implementation Method 2
An exemplary embodiment of the invention may further comprise at least one heating device associated with said battery pack, and wherein said control module is further configured, during charging of said battery pack, to compare said measured temperature with a second predetermined threshold temperature and, if said measured temperature is less than said second predetermined threshold temperature, cause said at least one heating device to be switched on until said measured temperature is at or above said second predetermined threshold temperature
Data Source
AI summary
A motor driven industrial actuator device includes an enclosure that houses: a motor, a control module, a drive, a battery pack and associated temperature sensor, and an input that receives an external power supply. The control module receives: the status of the external power supply, the charge state of the battery pack, the status of the battery pack, or the charge state and status of the battery pack. The control module causes the battery pack to be charged when an external power supply is present and the battery pack requires charging. During charging of the battery pack, the control module: receives the temperature associated with the battery pack from the temperature sensor; compares the measured temperature with a predetermined threshold temperature; and reduces the current to the battery pack if the measured temperature is greater than the predetermined threshold temperature.