LFP Battery APU with Active Voltage Control for Truck Alternator Charging
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Solution Overview
Problem
Existing electric auxiliary power units (APUs) in commercial trucks, which rely on conventional lead-acid batteries, suffer from limited runtime, insufficient power capacity, and rapid degradation, failing to provide adequate heating or cooling for extended rest periods, especially in extreme climates.
Innovation Solution
The implementation of lithium-ion battery-powered APUs with lithium iron phosphate (LFP) chemistry, featuring a battery module assembly with active voltage control and integrated battery management systems, allowing for faster charging and significantly longer cycle life, and capable of being recharged by the truck's alternator or truck stop electrification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional lead-acid batteries are used in electric APUs, then the system is simpler and cheaper to manufacture, but the runtime is limited and degradation is rapid
Solution Approach 1:
The patent changes the chemical composition parameters of the battery from conventional lead-acid to lithium-ion with LFP chemistry. This parameter change enables extended runtime (up to 13 hours) and improved cycle life (over 2000 cycles) while managing the complexity through integrated battery management systems that monitor and control the advanced chemistry.
Solution Approach 2:
The patent uses composite battery architecture combining lithium-ion cells with LFP chemistry, integrating multiple components including cell assemblies, modules, and management systems. This composite approach achieves both extended runtime and controlled complexity through systematic integration of advanced materials with management infrastructure.
2Reliability
If lithium-ion batteries with LFP chemistry are used, then cycle life is extended to over 2000 cycles, but manufacturing complexity increases
Solution Approach 1:
The patent segments the battery system into modular components: individual cells, cell assemblies, modules, and the complete battery pack. This segmentation enables standardized manufacturing of LFP chemistry components while simplifying assembly and maintenance, thereby improving ease of manufacture despite the advanced chemistry.
Solution Approach 2:
The battery management system performs multiple functions including monitoring cell voltage, temperature control, charge/discharge management, and safety protection. This multi-functional approach consolidates complexity into a single integrated system, making the manufacturing and operation of LFP batteries more manageable despite the advanced chemistry.
3Productivity
If lithium-ion batteries are used, then charging speed is faster and runtime is extended, but the system requires active voltage control
Solution Approach 1:
The battery management system implements feedback control by continuously monitoring cell voltage and state of charge, then adjusting the charging voltage and current accordingly. This feedback mechanism enables fast charging with lithium-ion batteries while preventing overcharge and managing the complexity of voltage control through automated regulation.
Solution Approach 2:
The charging system dynamically adjusts voltage and current parameters based on real-time battery state, transitioning between charging phases (constant current, constant voltage, tapering). This dynamic control optimizes charging speed while managing complexity through adaptive algorithms that respond to battery conditions rather than using fixed complex control circuits.
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
The lithium-ion battery-powered APUs provide extended runtime, maintaining higher charge capacity and degrading at a slower rate, enabling vehicles to operate for up to 13 hours without recharging and lasting over 2000 cycles, compared to 300-500 cycles of lead-acid batteries, thus ensuring comfortable rest periods without fuel consumption.
Implementation Method 1
rechargeable lithium-ion batteries
Implementation Method 2
recharged by the truck's alternator
Data Source
AI summary
Disclosed embodiments involve a rechargeable lithium-ion battery module assembly for use as an auxiliary power unit (APU), particularly in commercial trucks. Battery module assembly is recharged through the semi-trailer truck's alternator during engine operation. Battery module assembly has active voltage control capabilities to reduce charge time. Each battery array has two collector plate printed circuit board assemblies (PCBA) and two banks of lithium iron phosphate (LFP) battery cells. Individual battery cells are wire bonded to the collector plate PCBs, one of such PCBs incorporates a battery management system to monitor the electrical parameters and state of charge of the battery cells in the system. Battery cells are thermally coupled to an aluminum enclosure with a thermal gap filling material. Using different chemistries for the APU and the starting battery of the commercial truck, and methods of sequential charge and discharge cycles of each, without any other discrete device.