Trailer Battery Charging Interface With Safe High-Power Disconnect
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Solution Overview
Problem
Current power systems for towing-towed vehicle combinations are limited to low power levels (200-400 watts) and lack the capability to safely transfer high power (above 1 kW) due to safety and performance risks, and do not adequately sense battery status or charging limitations, posing risks to high-energy batteries like Li-Ion.
Innovation Solution
A power charging system with a charging device on the towing vehicle, controlled by a controller that communicates with an energy storage device on the towed vehicle, using high-power interfaces and safety mechanisms to transfer at least 1 kW of charging power safely, including alternators, converters, and safety interlocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If current power systems operate at 12V with 5-10A current capacity, then the system is simple and compatible with existing standards, but the power transfer capability is limited to 200-400W maximum
Solution Approach 1:
The patent increases the operating voltage from standard 12V to higher voltages (24V, 48V, or higher) to enable power transfer capabilities above 1kW. This parameter change allows the system to overcome the 200-400W limitation of conventional 12V systems while maintaining compatibility with existing vehicle electrical architectures through staged implementation.
2Power
If connectors are operated at higher power levels above 1kW, then the charging capability is improved, but safety and performance risks increase due to exposed and live voltage/current pins
Solution Approach 1:
The patent implements preliminary detection of connector insertion status before enabling high power transfer. The system detects whether the connector is properly engaged, and only then activates high voltage/current operation. This preliminary action prevents unsafe operation with exposed pins and ensures reliable electrical contact before high power charging begins.
Solution Approach 2:
The patent introduces an intermediary control system that mediates between the physical connector status and the high power electrical operation. This control system acts as a safety intermediary, verifying connector engagement and managing the transition to high power modes, thereby eliminating the direct risk of exposed live pins.
3Measurement precision
If the system only detects battery voltage, then the control system is simple, but the battery status sensing capability is insufficient for modern batteries like Li-Ion
Solution Approach 1:
The patent implements a multi-functional sensing system that can detect various battery parameters including voltage, current, temperature, and charge state. This universal sensing capability accommodates different battery types (lead-acid, Li-Ion, etc.) and provides comprehensive battery status information, enabling precise control while maintaining system adaptability.
Solution Approach 2:
The patent establishes feedback loops that continuously monitor battery status parameters and provide real-time information to the control system. This feedback mechanism enables dynamic adjustment of charging parameters based on actual battery conditions, improving both sensing precision and charging safety without requiring overly complex open-loop control systems.
4Duration of action of moving object
If the towing vehicle interface is powered when disconnected, then the system operates continuously, but hazardous conditions create risk of accidental electrical shock
Solution Approach 1:
The patent implements preliminary anti-action by detecting connector disconnection status and proactively de-powering the towing vehicle interface before hazardous conditions can develop. This preventive approach ensures that the interface is never powered when disconnected, eliminating the risk of accidental electrical shock while maintaining operational continuity when properly connected.
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 safe and efficient transfer of high power (up to 7 kW) to high-energy storage devices, preventing damage and hazards by monitoring battery conditions and ensuring safe disconnection.
Implementation Method 1
the charging device may be an alternator on the towing vehicle which is a generator driven by the engine of the towing vehicle
Data Source
AI summary
A power charging system for a towing vehicle and towed vehicle combination for transferring high charging power from a charging device in the towing vehicle to an energy storage device on the towed vehicle. The power charging system is capable of safely transferring at least 1 kW of charging power. The power charging system includes a controller and sensors operably coupled to the controller via a communication system for safely powering the system when needed to charge the energy storage device, and safely de-powering the system prior to disconnecting the high-power charging circuit between the towing vehicle and the energy storage device.