Motion-Sensing Battery Pack Charger for Vibration-Aware Current Derating
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Solution Overview
Problem
Charging batteries during transportation leads to increased terminal temperatures due to higher currents and vibrations, which can be mitigated by derating the power based on measured movement parameters.
Innovation Solution
A battery pack charger with a motion sensor and controller that adjusts the charging current based on detected vibrations, using derating values to reduce current flow during transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If charging current is increased to charge batteries during transportation, then charging speed is improved, but terminal temperature increases and safety deteriorates
Solution Approach 1:
The charging current is made dynamic rather than fixed. The controller continuously monitors movement parameters through sensors (accelerometers, gyroscopes) and adjusts the charging current in real-time based on detected vibrations and shocks. This allows the system to charge at high current when stationary or stable, and automatically reduce current when vibrations are detected, resolving the contradiction between charging speed and temperature control.
Solution Approach 2:
The system changes the operating parameters of the charging process based on environmental conditions. By monitoring movement parameters (acceleration, vibration frequency, shock intensity) and adjusting the charging current accordingly, the system adapts the electrical parameters to prevent excessive temperature rise during transportation while maintaining efficient charging when conditions permit.
2Temperature
If derating value is applied to reduce current during vibrations, then terminal temperature is controlled, but charging efficiency decreases
Solution Approach 1:
The derating value is dynamically adjusted based on real-time movement parameter measurements rather than applying a fixed reduction. The controller modulates the derating level according to vibration intensity and frequency, allowing maximum charging efficiency when conditions are favorable and applying only necessary derating when vibrations occur, thus minimizing the impact on overall charging efficiency while maintaining temperature control.
3Reliability
If movement sensors and control systems are added to adjust charging current, then charging safety during transport is improved, but device complexity increases
Solution Approach 1:
The controller integrates multiple functions into a single unit: it manages the charging current regulation, processes sensor data from movement detectors, determines derating values, and controls the power delivery. By combining these functions in one integrated controller rather than separate systems, the patent reduces overall device complexity while maintaining comprehensive safety features for chargeduring transportation.
Solution Approach 2:
The charging system monitors its own operating conditions through integrated sensors and automatically adjusts its behavior without external intervention. The controller self-regulates the charging current based on real-time vibration and shock detection, eliminating the need for complex external monitoring systems or manual intervention, thereby improving safety while keeping the system relatively simple.
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
Reduces terminal temperatures and enhances safety by dynamically adjusting the charging current in response to vibrations, thereby optimizing battery charging during transit.
Implementation Method 1
a sensor configured to measure a movement of the charger
Implementation Method 2
modify an amount of current provided to the battery pack over the one or more terminals based on the derating value
Data Source
AI summary
A device and method for charging a battery pack may include one or more charger terminals configured to connect to corresponding one or more battery pack terminals of a battery pack. The device may include a sensor configured to measure a movement of the charger. The device may include a controller electrically coupled to the sensor and configured to: receive, from the sensor, a movement parameter of the battery pack charger, determine a derating value based on the movement parameter, and modify an amount of current provided to the battery pack over the one or more terminals based on the derating value.