Modular Battery Control Apparatus with Latching Solenoids
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Solution Overview
Problem
Existing battery control systems for motor homes and boats are labor-intensive to assemble, prone to poor connections, and suffer from voltage drops and heat loss due to the use of heavy cables or copper bus bars for interconnections.
Innovation Solution
A modular design with three movable contactors built into a single housing, using latching solenoids and shared stationary contacts to reduce the number of connections, eliminate interconnection cables, and incorporate control circuitry that learns the solenoid polarity and monitors battery charge to prevent discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three individual contactors with heavy cables or copper bus bars are used for battery control, then reliable electrical connections are achieved, but assembly labor increases and voltage drops and heat loss occur
Solution Approach 1:
The patent combines three separate contactors into a single integrated contactor unit with a common housing and shared stationary contacts. This merging eliminates the need for multiple separate assemblies and heavy interconnection cables, reducing assembly labor while maintaining reliable electrical connections through the integrated design.
Solution Approach 2:
The integrated contactor unit performs multiple functions that previously required separate components: it provides battery isolation, load disconnection, and charger control all through a single unified device. This multi-functionality reduces the number of parts and assembly steps while ensuring consistent connection reliability across all functions.
2Power
If heavy cables or copper bus bars are used for interconnections, then adequate current carrying capacity is achieved, but voltage drops and heat loss increase
Solution Approach 1:
By integrating the contactors and eliminating intermediate cable connections, the patent removes the sources of voltage drops and heat loss that occur at connection points. The direct integration allows current to flow through solid welded connections within the housing rather than through external cables and bus bars, maintaining current carrying capacity while reducing energy losses.
3Adaptability or versatility
If three separate contactors are assembled individually, then each contactor can be optimized independently, but assembly complexity and labor increase
Solution Approach 1:
The patent merges three separately optimizable contactors into one integrated unit where the stationary contacts are common to all three movable contacts. This allows the design to maintain the benefits of individual optimization while eliminating assembly complexity through integration. The unified housing and shared contact structure reduce the number of assembly operations required.
4Use of energy by moving object
If latching solenoids are used instead of powered contactors, then battery discharge is prevented, but control circuit complexity increases
Solution Approach 1:
The latching solenoids use magnetic latching to maintain the closed contact position without continuous power, allowing the system to serve itself by maintaining state without external energy input. The control circuit only needs to provide momentary power to change state, significantly reducing battery discharge while the learning capability automates polarity detection to manage the increased control complexity.
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
This design reduces assembly labor, eliminates poor connections, voltage drops, and heat loss, while ensuring efficient battery management by eliminating the need for external power to hold contacts closed and preventing battery discharge.
Implementation Method 1
They incorporate the principles taught in U.S. Pat. No. 4,628,289 to Huber, using a magnet that is either attracted to the solenoid plunger or repelled, depending upon the polarity of the voltage applied to provide the latching.
Implementation Method 2
The magnet latch is attracted to the end of the plunger so that the plunger cannot return to its rest position when the power is removed.
Data Source
AI summary
A modular battery control apparatus includes a first stationary contact adapted for electrical communication with coach loads and a battery charger, a second stationary contact adapted for electrical communication with a coach battery, a third stationary contact adapted for electrical communication with a chassis battery, and a fourth stationary contact adapted for electrical communication with chassis loads and an alternator. First, second, and third movable contacts are respectively attached to first, second, and third latching solenoids and are adapted to abuttingly engage and disengage the respective first and second stationary contacts, second and third stationary contacts, and third and fourth stationary contacts. A controller selectively activates and deactivates the first, second, and third latching solenoids and a user-controlled switch panel communicates with the controller.