TRU Battery Self-Test Using Standby Power and Test Discharge
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Solution Overview
Problem
Existing battery health testing methods for transport refrigeration units (TRU) require continuous operation and cannot accurately assess battery health without operator intervention, leading to premature battery replacement or failure detection.
Innovation Solution
A battery health self-test protocol that detects connection to standby power, charges and discharges the battery using a test resistor, and calculates health assessment information, allowing for automated testing and replacement on an as-needed basis without requiring continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If continuous operation and operator intervention are required for battery health testing, then measurement precision is improved, but ease of operation deteriorates and loss of time increases
Solution Approach 1:
The battery health testing system performs self-diagnosis by automatically detecting its own voltage, current, and temperature parameters during charging and discharging cycles. The controller autonomously executes the testing protocol without requiring external operator intervention, enabling the system to serve itself for health assessment purposes.
Solution Approach 2:
The system performs battery health testing in advance during scheduled maintenance windows when the TRU is connected to external power sources. By conducting tests preliminarily before actual battery failure occurs, the system enables proactive replacement planning without affecting operational readiness.
2Extent of automation
If automated self-test protocol is implemented, then ease of operation is improved and loss of time is reduced, but device complexity increases
Solution Approach 1:
The existing TRU controller is enhanced to perform multiple functions: normal refrigeration control, battery management during operation, and battery health testing. By making the controller universal, the patent avoids adding separate dedicated testing hardware, thereby reducing overall system complexity while achieving automation.
Solution Approach 2:
A battery test resistor is introduced as an intermediary component that enables safe discharge testing without requiring complex external testing equipment. The resistor acts as a simple, reliable load that can be integrated into the existing battery circuitry, facilitating automated testing while maintaining system simplicity.
3Productivity
If battery testing is performed without recharging to full capacity, then productivity is improved, but reliability deteriorates
Solution Approach 1:
The system performs a preliminary charging phase to bring the battery to a known charge level before testing. This preliminary action ensures that the subsequent discharge test starts from a consistent state, enabling reliable health assessment without requiring the battery to be fully charged, thus balancing productivity and reliability.
4Reliability
If battery is replaced on prescribed schedule instead of as-needed, then reliability is improved, but loss of substance increases
Solution Approach 1:
The system provides continuous feedback on battery health status through the self-test protocol, enabling condition-based replacement decisions. When the battery health metric falls below a predetermined threshold, replacement is triggered. This feedback mechanism ensures replacement occurs only when necessary, preventing both premature replacement and failure-operated replacement.
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 accurate, automated battery health assessment and replacement, reducing unnecessary battery replacements and extending the life of batteries by testing and recharging them to full capacity without operator intervention.
Implementation Method 1
discharging the battery during a discharge cycle by coupling the battery to a battery test resistor
Data Source
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AI summary
Provided are a system (100) and method (200) for performing a battery health self-test protocol. Embodiments can include detecting a transport refrigeration unit (TRU) (10) is connected to standby power, and charging the battery (150) to a known charge level during a charge cycle. Embodiments can also include discharging the battery during a discharge cycle by coupling the battery to a battery test resistor, and calculating battery health assessment information for the battery.