Portable Charger Assembly for Remote Mining Sites

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Solution Overview

Problem

Remote worksites, such as underground mining sites, often lack readily available Direct Current (DC) power sources for charging battery systems, necessitating the transportation of chargers, which can be cumbersome and inefficient.

Innovation Solution

A portable charger assembly with a housing and a base designed for easy transportation, capable of converting Alternating Current (AC) to DC power, featuring a sturdy and compact design with vibration mounts for stability and protection from environmental elements, and adaptable for various transportation methods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If chargers are stationed or transported to remote worksites, then battery systems can be charged, but the complexity and inconvenience of operation increases

Engineering Contradiction:
Improvecharging capabilityVSAvoidtransportation convenience
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

The charger is integrated into a modular portable assembly that can be segmented into transportable components, allowing easy movement to remote sites while maintaining charging functionality

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The portable charger assembly serves multiple functions including charging, protection, and portability, eliminating the need for separate stationary infrastructure at remote worksites

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Object-affected harmful factors

If chargers are installed on concrete pads with barricades, then protection from environmental elements is improved, but the ease of transportation deteriorates

Engineering Contradiction:
Improveprotection from environmentVSAvoidtransportability
Core Design Contradiction:
Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The housing provides a protective shell that shields internal components from environmental elements while maintaining a lightweight, portable structure that can be easily transported

Inventive Principle:
Principle #30Flexible shells and thin films

Solution Approach 2:

The housing and mounting structure are designed to provide protective cushioning for internal components before exposure to harsh environments, eliminating the need for permanent protective infrastructure

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

3Stability of the object's composition

If the base has a complex structure with multiple portions and plates, then stability is improved, but the device complexity increases

Engineering Contradiction:
Improvebase stabilityVSAvoidbase structure
Core Design Contradiction:
Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The base is segmented into functional portions (first portion for mounting, second and third portions for stability) that work together to provide stability while maintaining a manageable structural complexity

Inventive Principle:
Principle #1Segmentation

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 portable charger assembly provides a reliable, efficient, and cost-effective solution for charging battery systems at remote sites, ensuring stable operation and easy transportation across rough terrains, while protecting internal components from debris and vibrations.

Implementation Method 1

capable of converting Alternating Current (AC) to DC power

Methodology Applied
Scientific EffectAC to DC conversion:

Implementation Method 2

featuring a sturdy and compact design with vibration mounts for stability and protection from environmental elements

Methodology Applied
Scientific EffectVibration damping: Damping

Data Source

PatentUS11631982B2Portable charger assembly operable to charge battery system
Publication Date: 2023.04.18 CATERPILLAR INC
  • US11631982B2 patent drawing
  • US11631982B2 patent drawing
  • US11631982B2 patent drawing

AI summary

A portable charger assembly operable to charge a battery system includes a housing defining a hollow space. The portable charger assembly also includes a charging module disposed within the hollow space of the housing. The charging module is adapted to provide power supply to the battery system. The portable charger assembly further includes a base adapted to be coupled with the housing. The base includes a base member including a first portion, a second portion, and a third portion. Each of the second and third portions is inclined relative to the first portion. The base also includes a first base plate fixedly coupled to the second portion of the base member. The base further includes a second base plate fixedly coupled to the third portion of the base member.