Removable Power Unit With Off-Board Battery Thermal Control
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Solution Overview
Problem
Electric drive work machines face challenges in maintaining battery health and environmental control when battery packs are disconnected from the machine, leading to potential downtime and reduced performance.
Innovation Solution
A self-contained power unit with an energy storage unit, thermal management system, and low-voltage system that includes a battery and controllers, allowing for monitoring and control of the energy storage unit in both connected and disconnected states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If battery packs are disconnected from the work machine for recharging, then recharging can be performed, but the ability to monitor and maintain battery health and environment is lost
Solution Approach 1:
The battery pack is designed with self-contained monitoring and thermal management systems that operate autonomously when disconnected from the work machine. The control unit continuously monitors battery parameters and the thermal management system actively regulates temperature, allowing the battery to maintain its health and environment independently during recharging operations.
2Loss of time
If battery swap is performed to reduce downtime, then energy can be replenished quickly, but the disconnected battery pack cannot maintain its state
Solution Approach 1:
The battery pack incorporates integrated control and thermal management systems that enable it to autonomously monitor its own state and regulate its thermal environment. This self-service capability ensures that even when disconnected during battery swaps or recharging, the battery maintains optimal performance and health conditions without requiring connection to the work machine.
3Device complexity
If functions for monitoring and controlling battery pack are only available when connected to work machine, then system complexity is reduced, but battery pack cannot be monitored when disconnected
Solution Approach 1:
The monitoring and control functions are segmented into two levels: a control unit within the battery pack that performs continuous local monitoring and thermal management, and a higher-level system in the work machine that provides additional oversight when connected. This segmentation allows the battery to maintain monitoring capabilities independently while reducing the overall system complexity burden on the work machine.
Solution Approach 2:
The control unit in the battery pack serves multiple functions: it monitors battery parameters, manages thermal conditions, and communicates with both the work machine and external charging systems. This multi-functionality enables the battery to be fully monitored and controlled whether connected to the work machine or disconnected for recharging, without proportionally increasing system 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
Enables continuous monitoring and control of the energy storage unit even when disconnected, improving battery health and reducing machine downtime by allowing for efficient battery swaps and recharging.
Implementation Method 1
a thermal management system configured to provide at least one of cooling or heating of the energy storage unit
Data Source
AI summary
A power unit may include an energy storage unit, a thermal management system configured to provide at least one of cooling or heating of the energy storage unit, and a low-voltage system. The low-voltage system may include a battery and one or more controllers, powered by the battery, configured to monitor and control the energy storage unit in both a connected state of the power unit and a disconnected state of the power unit. The power unit may include a power unit housing containing the energy storage unit, the thermal management system, and the low-voltage system. The power unit housing may be configured for removable connection to a frame of a machine.