Relay-Controlled Battery Charging for Outlet Current Limits
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Solution Overview
Problem
Charging multiple batteries with different operating potentials and capacities poses challenges, as concurrent charging can exceed the current capacity of an outlet, requiring operator intervention to manage sequential charging.
Innovation Solution
A battery charger system with multiple power channels, each equipped with a relay and current sensor, controlled by a controller that estimates current and manages relay states to maintain total current below a maximum limit, allowing for concurrent charging while preventing overload.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If concurrent charging of multiple batteries is enabled, then charging time is reduced and productivity is improved, but total current consumption exceeds the maximum current limit of the outlet
Solution Approach 1:
The system dynamically adjusts the charging state of multiple batteries by using relays to connect or disconnect batteries from the power source based on real-time current measurements. The controller continuously monitors total current consumption and adjusts which batteries are actively charging to maintain current below the maximum limit while maximizing charging productivity.
Solution Approach 2:
The system employs current sensors to continuously measure the total current being drawn from the power source and feeds this information back to the controller. The controller uses this feedback to determine which relays should be closed or opened to maintain optimal charging conditions without exceeding current limits.
2Object-affected harmful factors
If sequential charging is used to stay within current limits, then current overload is prevented, but operator intervention is required and productivity decreases
Solution Approach 1:
The system automatically manages the sequential charging process without requiring operator intervention. The controller autonomously monitors current levels, activates relays to connect appropriate batteries, and disconnects batteries when current limits are approached, enabling the system to self-regulate the charging sequence.
Solution Approach 2:
Relays serve as intermediary components between the power source and multiple batteries, allowing the controller to indirectly control which batteries receive power. This intermediary mechanism enables automatic current management without requiring direct operator manipulation of battery connections.
3Productivity
If multiple relays are closed to charge multiple batteries simultaneously, then charging capacity is increased, but total current exceeds the maximum current limit
Solution Approach 1:
The system dynamically determines the optimal number of relays to close based on real-time current conditions. Rather than having a fixed number of batteries charging simultaneously, the system adjusts the active charging configuration to maximize productivity while preventing circuit breaker tripping through continuous current monitoring and relay control.
Data Source
AI summary
A battery charger system includes multiple power channels to accommodate multiple battery chargers through a power input port. Each power channel includes a power outlet electrically coupled to the power input port through a relay. Each power channel further includes a current sensor. A controller is configured to estimate current in each of the power channels using the sensor signals, and configured to control the relays. The battery charger system is configured to provide power to the outlets by closing the corresponding relays, until the total current estimate is more than a maximum current limit, at which point the controller is configured to open the most recently closed relay. The controller is further configured to sequentially close remaining relays after the total current drops sufficiently, while maintaining the total current below the maximum current limit.