Propane Battery Charger Circuit for Self-Starting Off-Grid Charging
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Solution Overview
Problem
Conventional battery chargers lack a portable and efficient solution for charging battery packs, especially in remote or off-grid locations where traditional power sources are unavailable.
Innovation Solution
A portable propane-fueled battery charger that utilizes a propane-fueled engine to drive an alternator, generating electrical power to charge battery packs, with an electrical circuit that adjusts engine speed based on charging current demand and includes features for safe starting and efficient charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional battery charger is used, then charging can be performed in standard locations, but it cannot operate in remote or off-grid locations where traditional power sources are unavailable
Solution Approach 1:
The patent combines an internal combustion engine, alternator, and battery charger into a single integrated portable unit. The engine drives the alternator which generates electrical power to charge battery packs, creating a self-contained system that can operate independently of external power sources. This merging of functions enables the charger to be deployed in remote locations while maintaining a manageable single-unit form factor.
Solution Approach 2:
The device serves multiple functions: the engine provides mechanical power, the alternator converts it to electrical power, and the charger system charges battery packs. This multi-functionality allows a single device to replace what would otherwise require separate systems (power source, generator, and charger), enhancing adaptability to various operating conditions and locations.
2Productivity
If engine speed is increased to provide higher charging current, then charging speed improves, but energy efficiency decreases and fuel consumption increases
Solution Approach 1:
The system dynamically adjusts engine speed based on real-time charging requirements. The control system monitors the battery pack's charging state and modulates the engine RPM accordingly, increasing speed when higher current is needed and reducing speed when lower current suffices. This dynamic adjustment optimizes the balance between charging productivity and fuel efficiency, avoiding unnecessary energy consumption at high engine speeds when full power is not required.
Solution Approach 2:
The charging system incorporates feedback mechanisms that monitor charging current, battery state, and engine performance. This feedback information is used to continuously optimize engine operation, adjusting parameters such as fuel injection and ignition timing to maintain peak efficiency across varying operating conditions. The system learns and adapts to different charging scenarios, optimizing the trade-off between charging speed and fuel consumption based on actual performance data.
3Ease of operation
If the alternator is powered by the battery pack to start the engine, then starting is enabled without external power, but the battery pack is depleted during the starting process
Solution Approach 1:
The system performs preliminary charging of the battery pack using the alternator before the engine starts running. During the engine startup sequence, the alternator is already generating power to charge the battery, so the battery depletion during starting is minimal or negative (i.e., the battery gains charge rather than loses it). This preliminary action ensures that the battery is ready to provide starting current without suffering significant depletion, enabling truly self-contained operation.
Solution Approach 2:
The alternator begins charging the battery pack continuously from the moment the engine starts running, without interruption. This continuous charging action ensures that the battery pack is constantly being replenished during operation, offsetting any charge consumed during starting and maintaining the battery's charge level. The useful action of charging continues uninterrupted throughout engine operation, ensuring the battery remains charged and ready for the next starting cycle.
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 efficient and portable charging of battery packs in remote locations, providing a reliable power source for power tools and other devices using propane as a fuel, ensuring consistent and controlled charging operations.
Implementation Method 1
The alternator includes a rotor and stator coils. The output shaft is mechanically coupled to the rotor, the rotor is rotationally driven by the output shaft, and an electrical current is induced in the stator coils by rotation of the rotor.
Implementation Method 2
The engine includes an output shaft and is configured to receive propane via the propane fuel line and rotationally drive the output shaft.
Data Source
AI summary
One embodiment provides an electrical circuit coupled to an alternator. The electrical circuit includes a rotor and stator coils. The electrical circuit is configured to receive, at a point when an engine is operating, an electrical current that is induced in the stator coils by rotation of the rotor and charge a battery pack with the electrical current and inhibit generation of a spark by the engine while the alternator is powered by the battery pack until a speed of the alternator is greater than a threshold. The electrical circuit is further configured to power the alternator, at a point when the engine is not operating, with electrical current supplied by the battery pack coupled to a battery connector to start the engine.