Self-Powered Battery Heater for Cold Weather Start
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Solution Overview
Problem
Batteries used in aircraft and other devices face challenges in cold temperatures, where frozen electrolytes increase internal resistance, preventing the battery from producing sufficient current to start engines or power devices, and reliance on external power sources may not be feasible in remote locations.
Innovation Solution
A self-powered battery heater system that uses the battery's electrochemical cells to discharge electrical energy intermittently, determining power-on and power-off time periods to warm the battery without external power, allowing it to maintain voltage and current for engine starting or device operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery is removed from the aircraft and placed in a temperature-controlled environment, then the electrolyte freezing is prevented, but the operation becomes difficult and time-consuming especially by personnel wearing cold weather clothing and gloves
Solution Approach 1:
The battery heater system uses the battery's own stored energy to heat itself, eliminating the need for external power sources or manual removal. The control system automatically manages the heating process based on temperature sensors, making the battery self-sufficient in cold environments.
Solution Approach 2:
The heater system activates before the battery is needed, pre-heating the battery to prevent electrolyte freezing. This preliminary action ensures the battery is ready for operation without requiring last-minute removal or manual intervention.
2Ease of operation
If the battery operates in cold temperatures with frozen electrolyte, then the battery remains in place, but the internal resistance increases and prevents sufficient current production
Solution Approach 1:
The heater system operates in periodic cycles, turning on to heat the battery when temperature drops below threshold, and turning off when the target temperature is reached. This periodic heating maintains the battery above freezing without continuous energy consumption.
Solution Approach 2:
The system changes the temperature parameter of the battery from frozen/cold states to above-freezing states by applying heat. This parameter change restores the electrolyte's流动性 and reduces internal resistance, enabling normal current production.
3Temperature
If an external power source is used to operate the battery heater, then the battery can be heated, but external power sources may not be available at small airports or remote cold weather locations
Solution Approach 1:
The battery heater system is self-powered, drawing energy from the battery's own stored capacity. This eliminates dependence on external power infrastructure, enabling operation at remote airports and cold weather locations where no external power is available.
Solution Approach 2:
The battery serves dual functions: as an energy storage device and as a power source for its own heating system. This multi-functionality ensures the battery can operate independently in various environments without requiring external support systems.
4Productivity
If the heater operates at consistent power level to reach target temperature, then the heating is efficient, but the battery voltage drops and may not sustain full power heating
Solution Approach 1:
The heater operates in periodic on/off cycles rather than continuously at full power. The control system monitors battery voltage and temperature, activating the heater only when needed to maintain target temperature, thus preserving battery power while achieving effective heating.
Solution Approach 2:
The system uses temperature sensors and voltage monitoring to provide feedback to the control logic. This feedback enables the heater to adjust its operation dynamically, maintaining efficient heating while responding to battery power availability and preventing voltage collapse.
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 batteries to self-heat without removal from cold environments and independence from external power sources, ensuring reliable operation by reducing electrolyte freezing and maintaining necessary voltage and current levels.
Implementation Method 1
discharging the electrochemical cells through the heater
Data Source
AI summary
A battery heater system for a battery used in cold weather operations and methods for using the battery heater system are described. Embodiments of the battery heater system may incorporate a heater switch with an indicator, a timer circuit, a controller, a voltage meter, a temperature transducer, and a heating element. In some methods of using the device, the battery powers the heating element for a fixed cycle time based on the time to discharge the battery at a cold-soaked temperature. In other methods of using the device, the battery powers the heating element for a varying cycle time as necessary to discharge the battery to a discharge cut-off voltage value. In other methods of using the device, the heating element is operated using a duty cycle that is varied based on the battery temperature.