Industrial Truck Battery Control With Plug-In Power Sharing
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Solution Overview
Problem
Existing industrial trucks with battery-powered drives face limitations in charging flexibility, as they typically require external charging stations and lack dynamic recharging capabilities during operation.
Innovation Solution
The industrial truck is equipped with a main battery and plug-in batteries, along with a control module that manages operating and charging modes. These modes include reduced power operation, power optimization, plug-in battery charging, and auxiliary charging, allowing for flexible charging and power management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If external charging stations are used for recharging batteries, then the truck can be recharged, but the charging flexibility is limited and requires the truck to be stopped at external charging devices
Solution Approach 1:
The battery system is segmented into a main battery and removable plug-in batteries. The plug-in batteries can be independently exchanged or used to extend operational capacity, allowing the truck to continue operating while one battery is being recharged externally, thus reducing operational downtime and improving charging flexibility
Solution Approach 2:
Batteries are recharged in advance using external charging stations before being installed in the truck. This preliminary charging action allows the truck to start operations immediately with fully charged batteries, eliminating wait time during operational periods and improving overall charging flexibility
2Adaptability or versatility
If inductive power supply is used for dynamic recharging during operation, then recharging during operation is enabled, but the cost increases due to expensive floor charging coils
Solution Approach 1:
Removable plug-in batteries serve as intermediaries between external charging infrastructure and the truck's power system. These batteries can be charged externally in advance and then installed in the truck to provide power during operations, enabling dynamic recharging capability without requiring expensive inductive charging coils to be installed in the warehouse floor
Solution Approach 2:
The system uses relatively inexpensive, replaceable plug-in batteries instead of expensive permanent inductive charging infrastructure. These batteries can be economically replaced or recharged as needed, providing a cost-effective alternative to high-infrastructure-cost inductive power supply systems
3Power
If the main battery provides maximum output power, then the power supply is sufficient for high-demand operations, but the operational duration is limited
Solution Approach 1:
The system merges the main battery with one or more plug-in batteries to create a combined power system. When plug-in batteries are installed, they contribute additional capacity to the main battery, extending the operational duration while maintaining the ability to provide maximum output power when needed
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
This solution enables flexible charging during operation, extends the truck's operational period by utilizing plug-in batteries, and reduces the need for external charging infrastructure, enhancing overall system flexibility and efficiency.
Implementation Method 1
a battery charger is provided, via which the main battery can be charged and discharged
Implementation Method 2
a power optimized operating mode is provided, in which the control module is operated to provide an amount of power such that at least one plug-in battery is contributing additionally to the power supply of the truck
Implementation Method 3
a plug-in battery charging mode is provided, in which the control module is configured to draw charging power from at least one plug-in battery to re-charge the main battery
Data Source
Figure 1
Figure 2
AI summary
Industrial truck comprising at least one battery-powered drive, which has a main battery carried along for electrical supply and further comprising a battery charger via which the main battery can be charged and discharged, wherein at least one plug-in location is provided for one or more plug-in batteries, which plug-in location has electrical contacts for connection to a control module for each plug-in battery, the control module being configured to control at least two of the following operating and/or charging modes on the industrial truck: - A reduced power operating mode, in which the control module is operated to draw power at a rate at which the power drawn from the main battery is less than a maximum output power of the main battery, - A power optimized operating mode, in which the control module is operated to provide an amount of power such that at least one plug-in battery is connected additionally and supplies energy, - A plug-in battery charging mode in which the control module is operated to draw a charging power from at least one plug-in battery for the main battery; and - A charger charging mode in which at least one plug-in battery is charged from the battery charger.