Vehicle Battery Charging Rate Control for Manufacturing Delays
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Solution Overview
Problem
In vehicle manufacturing factories, remote-controlled vehicle running times can exceed planned durations due to manufacturing delays, leading to excessive battery power consumption and potentially lower than target State of Charge (SOC) levels.
Innovation Solution
A charging system that adjusts the charging rate based on manufacturing status deviations by calculating a running reduction SOC and determining a mounting time SOC using a charging rate determination unit, ensuring the SOC at the post-process part meets or exceeds the target value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the vehicle runs on track by remote control for longer than planned due to manufacturing delays, then the manufacturing flexibility is improved, but the battery power consumption increases and the charge rate (SOC) becomes lower than the target value
Solution Approach 1:
The system performs preliminary calculation of the required charge rate at mounting time based on predicted manufacturing status deviations. By pre-determining the necessary charging rate before the vehicle actually runs the track, the system can adjust the charging process in advance to compensate for anticipated delays, ensuring the vehicle arrives with sufficient SOC regardless of actual running duration.
Solution Approach 2:
The system continuously monitors actual manufacturing status and compares it with the plan, then feeds this information back to adjust the charge rate determination. This closed-loop feedback mechanism allows real-time adaptation: when delays are detected, the system increases the charging rate at mounting time to compensate for extended running duration, maintaining SOC above target levels.
2Reliability
If the charging rate at mounting time is increased to compensate for manufacturing delays, then the SOC at post-process part is maintained above target value, but the charging system complexity increases
Solution Approach 1:
The system changes the parameter of charging rate based on manufacturing status deviations. Instead of using a fixed charging rate, the system dynamically adjusts the charging rate at mounting time as a variable parameter that responds to actual manufacturing conditions, allowing SOC maintenance without complex hardware modifications.
Solution Approach 2:
The charging system serves itself by using its own charging infrastructure to provide the additional charge needed. The system determines the required charge rate and executes the charging through existing charging devices, eliminating the need for external complex control systems or additional energy storage devices.
3Productivity
If the charging rate is adjusted based on manufacturing status, then the productivity is improved by preventing undercharging, but the control system complexity increases
Solution Approach 1:
The manufacturing status acquiring unit and charge rate determination unit serve multiple functions: they not only determine charging rates but also monitor manufacturing progress, predict deviations, and coordinate with vehicle scheduling. This multi-functionality reduces the need for separate dedicated systems, achieving productivity improvement with moderate control complexity.
Data Source
AI summary
A charging system includes a remote control unit runs the vehicle in the manufacturing process of the factory, the vehicle being capable of running on a track in the factory by remote control, the vehicle including a communication device and a secondary battery for running the vehicle on the track is mounted on the vehicle before running the track; a manufacturing status acquiring unit acquires a manufacturing status in a post-process part that is a destination of the vehicle running from a pre-process part where the secondary battery mounted on the vehicle is charged or a pre-charged secondary battery is mounted; and a charging rate determination unit determines a charging rate at the time of mounting using the acquired manufacturing status in the post-process part, the charging rate at the time of mounting being a charging rate of the battery at the time of mounting the secondary on the vehicle.