Remote Battery Charger Dynamic Voltage Control
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Solution Overview
Problem
Conventional remote battery chargers for trailers in the trucking industry often fail to maintain sufficient power levels, leading to accidents and reduced battery life due to inappropriate voltage and current adjustments, and require additional hardware for different battery chemistries and temperature monitoring, resulting in inefficient charging.
Innovation Solution
A remote battery charger with a DC/DC converter and controller that dynamically adjusts output current and voltage based on input voltage, temperature, and battery chemistry, eliminating the need for external shutdown triggers and supporting multiple battery types through multi-stage charging and extended charging capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional remote battery chargers monitor internal temperature and reduce charging voltage and current, then charging safety is improved, but charging efficiency deteriorates due to unnecessary current reduction
Solution Approach 1:
The patent introduces an external temperature sensor as an intermediary measurement device that monitors battery temperature directly at the battery location, rather than relying on the charger's internal temperature sensor. This external sensor serves as a mediator between the battery and the charger's control system, providing accurate temperature data for charging adjustments without being affected by the charger's own thermal conditions.
2Device complexity
If conventional remote battery chargers use fixed target voltage throughout charging, then device complexity is reduced, but battery life deteriorates due to overcharging or undercharging
Solution Approach 1:
The patent implements multi-stage charging with dynamically adjusted target voltages based on battery state of charge and temperature conditions. The charging process transitions through multiple phases (bulk charging, absorption charging, float charging) with different voltage targets, replacing the simple fixed-voltage approach. This dynamic voltage adjustment optimizes battery life by preventing overcharging and undercharging while maintaining manageable system complexity through automated stage transitions.
Solution Approach 2:
The system changes charging parameters (voltage, current) based on battery state of charge and temperature conditions. Different charging stages utilize different voltage targets and current rates, with parameters automatically adjusted as the battery charges. This parameter variation optimizes battery life and charging efficiency while the control system manages the complexity of multiple parameters through standardized charging protocols.
3Adaptability or versatility
If conventional remote battery chargers require separate controllers for different battery chemistries, then adaptability to different battery types is reduced, but device complexity increases due to additional hardware
Solution Approach 1:
The patent implements a universal charging controller that can handle multiple battery chemistries (lead-acid, lithium-ion, nickel-cadmium) through software-based charging algorithms rather than requiring separate hardware controllers for each battery type. The single controller adapts to different battery chemistries by selecting appropriate charging profiles, voltage targets, and current rates based on detected battery type or user selection, thereby achieving broad compatibility without increasing hardware complexity.
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
Ensures safe and efficient charging by maintaining minimum voltage levels, reducing unnecessary shutdowns, and adapting to different battery chemistries, thereby enhancing battery life and operational safety.
Implementation Method 1
The remote battery charger accepts an input current and voltage from the tractor battery and converts it to an output current and voltage suitable for charging the remote battery
Data Source
AI summary
A battery charger device and controller is provided. The battery charger includes a DC/DC converter operative to convert an input current and an input voltage to an output current and an output voltage. The controller is configured to determine whether the input voltage is between a minimum voltage and a maximum voltage and dynamically adjust the output current based on the determination that the input voltage is between the minimum voltage and the maximum voltage.