Lift Gate Power Module Using Super Capacitors for Battery Run-Down
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Solution Overview
Problem
The existing battery systems used to power lift gates on delivery trucks face frequent run-down due to long cable lengths causing voltage loss, temperature extremes, and infrequent recharging, leading to costly service calls and reduced battery life.
Innovation Solution
A hybrid power module combining a super capacitor bank and a battery, with an integrated DC/DC boost converter, positioned near the lift gate to efficiently recharge and extend battery life by utilizing the alternator's energy, and capable of powering the lift gate motor for multiple cycles without the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate battery is used to power the lift gate, then the lift gate can operate independently, but the battery experiences frequent run-down due to long cable lengths causing voltage loss
Solution Approach 1:
The patent divides the power system into two segments: the vehicle's main battery system and a separate lift gate battery system. This segmentation allows the lift gate battery to be positioned close to the alternator, eliminating the voltage loss issue caused by long cable lengths while maintaining independent operation capability.
Solution Approach 2:
The patent introduces a voltage regulator/charger as an intermediary device that manages power flow between the alternator and the lift gate battery. This intermediary ensures efficient charging while preventing overcharging, thereby reducing energy loss and extending battery life.
2Ease of manufacture
If the lift gate battery is positioned away from the alternator, then installation is easier, but recharging efficiency decreases due to line loss
Solution Approach 1:
The patent changes the electrical parameters by using a DC-DC converter that can operate with a wide range of input voltages. This allows the system to accommodate longer cable lengths without significant energy loss, as the converter can efficiently step up or step down voltages to maintain optimal charging conditions regardless of cable length.
3Device complexity
If traditional battery systems are used, then the system is simple, but battery life is reduced due to frequent run-down and temperature extremes
Solution Approach 1:
The patent implements a voltage regulator with overcharge protection and temperature compensation features that cushion the battery against damaging conditions before they can cause harm. This prior protection extends battery life by preventing voltage extremes and temperature-related damage.
Solution Approach 2:
The patent incorporates feedback mechanisms through voltage regulators and charge controllers that continuously monitor battery status and adjust charging parameters accordingly. This feedback system prevents overcharging and optimizes charging rates based on battery condition, thereby extending battery life while maintaining manageable system complexity.
4Use of energy by moving object
If the battery is recharged frequently, then energy availability is maintained, but maintenance costs increase due to service calls
Solution Approach 1:
The patent implements a self-charging system where the lift gate battery automatically recharges from the alternator during vehicle operation. The voltage regulator and charge controller enable this self-service functionality, maintaining energy availability without requiring manual intervention or costly service calls.
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 hybrid power module effectively addresses battery run-down issues by reducing recharging time, extending battery life, and preventing lift gate malfunction, thereby reducing maintenance costs and ensuring continuous truck operation.
Implementation Method 1
The alternator includes a rotor shaft that is turned by a pulley and drive belt system. When the engine is started, the pulley turns the rotor shaft, causing the rotor to act as a spinning electro-magnet. As the pulley is rotated, alternating current (AC) passes through a magnetic field and an electrical current is generated.
Implementation Method 2
The electrical energy generated by the alternator and battery together must be adequate to support the vehicle's so-called hotel load.
Data Source
AI summary
A hybrid power module is provided. The power module is associated with a truck having a lift gate. The power module includes a super capacitor comprising a bank of capacitors, with the super capacitor being in electrical communication with an alternator of the truck. The power module also includes a battery, a switch, a DC/DC boost converter, and electrical wiring. The electrical wiring connects the capacitor bank and first battery to the switch, and further connects the switch to a motor for the lift gate. The super capacitor and the first battery are positioned in parallel, with the super capacitor and the first battery residing proximate the lift gate. The super capacitor contains enough energy to power the electric motor for the lift gate through at least two operating cycles without the battery, protecting the lift gate if the battery goes weak.