Modular High-Voltage Battery System for Industrial Trucks
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Solution Overview
Problem
Existing traction batteries in industrial trucks face limitations in rapid charging due to low operating voltages, leading to long charging times and the need for multiple battery developments for different voltage requirements, which is inefficient and costly.
Innovation Solution
A modular system featuring a high-voltage battery housing with a voltage converter that can adjust the operating voltage to match different industrial truck requirements, allowing direct high-voltage charging and using multiple voltage converters to support various standard voltages such as 24 V, 48 V, and 80 V, enabling quick charging without significant design adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional low-voltage traction batteries (24V-80V) are used, then compatibility with existing drive concepts is maintained, but charging time becomes excessively long
Solution Approach 1:
A voltage converter is introduced as an intermediary device between the high-voltage battery (400V) and the forklift's electrical system. This mediator enables fast charging by accepting high-voltage input while converting it to the lower operating voltages (24V, 48V, or 80V) required by the forklift, thus resolving the contradiction between charging speed and system compatibility
Solution Approach 2:
The system changes the voltage parameter by using a high-voltage battery (400V) instead of conventional low-voltage batteries, and employs a voltage converter to adapt this parameter to match different forklift requirements. This parameter transformation enables fast charging while maintaining compatibility with existing drive concepts operating at various voltage levels
2Productivity
If a high-voltage battery system is implemented, then fast charging capability is achieved, but modifications to the electrical system are required
Solution Approach 1:
The voltage converter is designed with multi-functionality to handle multiple operating voltages (24V, 48V, 80V) and different forklift models. This universal design reduces the need for extensive modifications across different electrical systems, as a single converter unit can adapt to various voltage requirements, thereby reducing overall system complexity
Solution Approach 2:
The voltage converter acts as a buffer between the high-voltage battery and the forklift's electrical system, isolating the modifications required for fast charging from the existing drive concept. This intermediary approach minimizes the scope of modifications needed in the forklift's original electrical system while still enabling high-speed charging
3Adaptability or versatility
If multiple battery variants are developed for different voltage requirements, then specific forklift models are optimized, but development costs and complexity increase
Solution Approach 1:
Instead of developing multiple battery variants, the invention uses a single universal high-voltage battery design (400V) combined with a voltage converter that can output multiple voltages (24V, 48V, 80V). This universal approach eliminates the need for separate battery development for different forklift models, significantly reducing development effort and manufacturing complexity while maintaining adaptability across various voltage requirements
4Loss of time
If high-power charging current is used, then charging time is reduced, but heat generation and cable size increase
Solution Approach 1:
The system changes the charging parameter by using high voltage (400V) with moderate current instead of low voltage with high current. This parameter transformation reduces heat generation (since P=VI, and higher voltage allows lower current for the same power) and enables the use of smaller, more manageable cables while still achieving fast charging
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 modular system enables rapid charging of traction batteries, reduces the need for multiple battery developments, and allows for the use of largely identical components across different industrial trucks, enhancing operational efficiency and reducing costs.
Implementation Method 1
a high-voltage battery (400 V) as an energy storage device
Implementation Method 2
an optional voltage converter that can be inserted into the housing to provide an operating voltage for the forklift truck
Data Source
Figure 1
Figure 2
Figure 3
AI summary
In a modular system for a fast-charging traction battery (1) for a forklift truck with a battery housing and a high-voltage battery (2) as an energy storage device (14) and with an optional voltage converter (5) that can be inserted into the housing to provide an operating voltage for the forklift truck at a discharge port (6), the traction battery (1) can be designed in at least a plurality of variants for different operating voltages, wherein, in addition to a direct transmission of the voltage of the battery (2), at least one voltage converter (5) is used or alternatively, a plurality of voltage converters (5) for different operating voltages.