Power Distribution Unit With Single Contactor for Battery Heating and Charging
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Solution Overview
Problem
Conventional power machines, particularly those used for mowing operations, face challenges in efficiently managing electrical power distribution for battery-based systems, including heating and charging, which affects the performance and longevity of batteries.
Innovation Solution
A power distribution unit (PDU) is configured to control the flow of electrical current for charging, heating, and pre-charging batteries, utilizing a single contactor that can switch between open and closed states to isolate or connect terminals for battery heating, charging, and powering loads, ensuring efficient energy management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a power distribution unit uses multiple contactors to control battery heating, charging, and power distribution separately, then the control precision and reliability are improved, but the device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines multiple contactor functions into a single contactor that controls heating, charging, and power distribution circuits simultaneously. This single contactor integrates the functions that would traditionally require separate contactors, reducing device complexity while maintaining control reliability through unified management of all electrical circuits.
Solution Approach 2:
The single contactor in the power distribution unit is designed to perform multiple functions: controlling the heating circuit, the charging circuit, and the power distribution circuit. This multi-functional design eliminates the need for separate contactors for each circuit, simplifying the overall system architecture while ensuring reliable control across all operations.
2Measurement precision
If a power distribution unit uses multiple contactors for separate circuit control, then the control precision is improved, but the manufacturing costs increase
Solution Approach 1:
The patent merges multiple contactor components into a single integrated contactor unit that manages heating, charging, and power distribution circuits. This consolidation reduces the number of parts that need to be manufactured, assembled, and tested, thereby lowering manufacturing costs while maintaining precise control through the unified contactor design.
Solution Approach 2:
The single contactor is designed with universal functionality to control multiple circuits (heating, charging, and power distribution) with precise control. This multi-functional approach eliminates the need for multiple specialized contactors, reducing manufacturing complexity and cost while preserving the precision required for each specific circuit control.
3Reliability
If the power distribution unit isolates terminals using open contactor state, then the safety and reliability are improved, but the operational efficiency decreases due to frequent switching
Solution Approach 1:
The power distribution unit performs preliminary isolation of terminals by maintaining the contactor in an open state during non-operational periods or when circuits are not required. This preliminary safety measure ensures that terminals are isolated before any potential hazardous conditions can develop, while the system quickly transitions to closed state when operation is needed, minimizing the impact on operational efficiency.
Solution Approach 2:
The contactor dynamically switches between open and closed states based on real-time operational requirements and safety conditions. This dynamic control allows the system to maintain safety by isolating terminals when necessary while minimizing the duration of isolation to preserve operational efficiency. The rapid switching capability ensures that safety measures do not significantly impact overall system productivity.
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 PDU enables effective battery heating, charging, and power distribution, enhancing battery performance and longevity by optimizing energy flow and reducing complexity and manufacturing costs.
Implementation Method 1
a heating circuit (362) in an active state to supply heat to the battery (320)
Implementation Method 2
a charger (354) configured to supply an electrical current to charge the battery (320)
Data Source
AI summary
Power systems are provided for a power machine, including power machines having a battery and a motor arranged to be powered by the battery. A first switch can be switched between open and closed states to control charging, pre-heating, or other operations for the battery and for the power system as a whole.