Electric Lift Battery Heating and Charge Control in Cold Operation
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Solution Overview
Problem
Traditional lift devices rely on hydraulic systems, which require reservoir tanks and hydraulic fluids, leading to maintenance challenges and environmental concerns, while also lacking efficient battery management systems for electric operation.
Innovation Solution
A fully-electric lift device equipped with a rechargeable battery system, a heating system, and a control system that manages battery usage and limits operational speeds based on current delivery and regeneration limits, eliminating the need for hydraulic systems and allowing simultaneous battery charging and heating without external power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic systems are used to power lift devices, then lifting capability is achieved, but maintenance requirements increase and environmental harm occurs due to hydraulic fluids
Solution Approach 1:
The patent replaces the hydraulic mechanical system with an electric system. Electric motors powered by a battery pack substitute for hydraulic cylinders, eliminating the need for hydraulic fluid and associated maintenance while reducing environmental contamination risks.
Solution Approach 2:
The patent removes the hydraulic system components (hydraulic fluid, reservoirs, hoses, pumps) from the lift device and replaces them with electric components. This extraction of the harmful hydraulic subsystem achieves maintenance-free operation and eliminates fluid contamination concerns.
2Duration of action of moving object
If battery capacity is increased to extend operation time, then duration of action improves, but weight of the system increases
Solution Approach 1:
The control system dynamically manages battery power distribution based on real-time operational demands. By optimizing power delivery to different components (drive motors, linear actuators, heating system) and using regenerative braking to recharge the battery, the system extends operation time without requiring excessive battery capacity and associated weight.
Solution Approach 2:
The regenerative braking system continuously recovers energy during descent and braking operations, feeding it back to the battery. This continuous energy recovery extends the effective operation time without requiring a proportionally larger battery, thus avoiding excessive weight increase.
3Reliability
If heating power is increased to maintain battery temperature in cold environments, then battery performance is maintained, but energy consumption increases
Solution Approach 1:
The control system continuously monitors battery temperature and dynamically adjusts heating power accordingly. Heating is activated only when the battery temperature falls below a predetermined threshold, and the heating intensity is modulated based on the actual temperature deviation from the optimal range, minimizing energy consumption while maintaining battery performance.
Solution Approach 2:
The system changes the heating parameter (power level) based on the battery temperature condition. Instead of continuous high-power heating, the system applies variable heating power only when and where needed, optimizing the balance between maintaining battery performance and minimizing energy consumption in cold environments.
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 solution enables efficient, maintenance-free, and environmentally friendly operation of lift devices by using electric motors and actuators, optimizing battery performance, and eliminating the need for hydraulic fluids, while ensuring reliable operation across varying temperatures.
Implementation Method 1
The heating system includes a heater configured to heat the battery when the temperature of the battery falls below a predetermined threshold
Implementation Method 2
The battery charger is configured to selectively charge the battery and to selectively charge the heating system
Implementation Method 3
The linear actuator is configured to selectively move a work platform configured to support a load between a raised position and a lowered position. The linear actuator has an electric motor.
Implementation Method 4
The drive motor is configured to rotate at least one wheel of the plurality of wheels to propel the lift device
Data Source
AI summary
A lift device comprises a base, a linear actuator, and a rechargeable battery system. The linear actuator is configured to selectively move a work platform between a raised position and a lowered position. The linear actuator includes an electric motor. The rechargeable battery system includes a battery, a heating system, and a battery charger. The battery is configured to power the electric motor of the linear actuator. The battery charger is configured to simultaneously charge the battery and provide power the heating system to heat the battery.