Multi-Voltage Electrical Architecture for Charging Machines in Motion
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Solution Overview
Problem
Battery powered machines face challenges in managing different power level requirements for various electrical elements, necessitating multiple power sources and efficient power distribution systems, particularly in large machines like mining trucks, where high power transfer rates are needed while adhering to regulatory and component limitations.
Innovation Solution
An electrical architecture with at least two different voltage buses, incorporating AC/DC and DC/DC converter circuits, allows power transfer and charging while the machine is in motion or stationary, using an external power source to charge the battery module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple power sources and voltage buses are used to meet different power level requirements, then the machine can operate efficiently with various electrical elements, but the device complexity increases
Solution Approach 1:
The electrical architecture is segmented into multiple voltage buses (first voltage bus and second voltage bus) with different voltage levels. Each bus serves specific electrical elements with appropriate power requirements, allowing efficient power distribution while managing complexity through structured segmentation.
Solution Approach 2:
DC/DC converter circuits are introduced as intermediary devices between the first voltage bus and the second voltage bus. These converters enable controlled power transfer and voltage transformation, facilitating coordination between different power sources and electrical elements while maintaining system manageability.
2Productivity
If high power transfer rates are implemented to charge the battery module, then charging efficiency improves, but regulatory and component limitations may be exceeded
Solution Approach 1:
The electrical architecture dynamically adjusts power transfer rates based on system state and requirements. The DC/DC converter circuits can modulate power flow to achieve high charging rates when conditions permit, while automatically reducing rates to comply with regulatory and component limitations, ensuring both productivity and reliability.
Solution Approach 2:
The system changes operational parameters (voltage, current, power rate) based on real-time conditions. By transforming power at different stages through AC/DC and DC/DC converters, the architecture can optimize charging speed while maintaining compliance with external constraints through parameter adjustment.
3Ease of manufacture
If the machine is charged while stationary using AC/DC converter, then charging infrastructure is simpler, but the machine cannot be charged during operation
Solution Approach 1:
The electrical architecture incorporates dual charging capability through multiple converter circuits. The AC/DC converter enables stationary charging when the machine is stopped, while the DC/DC converter enables charging during motion from external power sources. This multi-functionality allows the system to adapt to different operational scenarios and charging needs.
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
Enables high power transfer rates to battery powered machines, allowing them to operate efficiently and be charged while moving, while complying with regulatory and market constraints.
Implementation Method 1
an AC/DC converter circuit coupled to the first voltage bus and configured to charge the battery module while the battery powered machine is stationary
Implementation Method 2
a first DC/DC converter circuit coupled between the first voltage bus and a second voltage bus, wherein the first DC/DC converter circuit is configured to generate a second voltage at the second voltage bus
Implementation Method 3
a battery module configured to supply a first voltage to a first voltage bus
Data Source
AI summary
An electrical architecture that allows power to be transferred to a battery powered machine while the machine is moving and that allows the machine to be charged while stationary.