Industrial Vehicle Battery Electrolyte Level Control
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Solution Overview
Problem
Industrial vehicles equipped with lead-acid batteries face battery deterioration due to repeated charging and discharging, especially when the electrolyte level is low, leading to reduced battery life and inconvenience in refilling, as existing systems only provide warnings without measures to prevent deterioration during discharging.
Innovation Solution
An industrial vehicle with an electrolyte level sensor, a vehicle operating time calculator, a data-storing device, and a motor controller that limits the electric motor's operation based on the detected low electrolyte level, gradually reducing torque or speed to prevent battery deterioration and alert the operator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery is refilled with electrolyte solution only when warned, then the battery deterioration is prevented, but the vehicle operation is interrupted and productivity is reduced
Solution Approach 1:
The patent applies dynamics by making the motor output dynamically adjustable based on electrolyte level. Instead of a static stop-warning system, the motor controller continuously adjusts output to match battery capacity, allowing operation to continue while preventing deterioration. This resolves the contradiction by enabling both productivity maintenance and battery protection through adaptive control.
Solution Approach 2:
The patent changes the parameter of motor output based on electrolyte level detection. When electrolyte level is low, the system changes motor output parameters (reducing power) rather than completely stopping operation. This allows the vehicle to remain operational while protecting the battery, simultaneously achieving productivity maintenance and reliability improvement.
2Reliability
If the vehicle is stopped immediately when electrolyte level is low, then battery deterioration is prevented, but the operator convenience is reduced and refilling becomes inconvenient
Solution Approach 1:
The system dynamically adjusts motor output rather than statically stopping the vehicle. This allows the operator to continue working with reduced power, maintaining ease of operation while still protecting the battery from deterioration. The operator experiences no abrupt interruption and can plan refilling at convenient times.
Solution Approach 2:
The system provides beforehand cushioning by gradually reducing motor output as electrolyte level decreases, rather than abruptly stopping. This cushioning approach prevents sudden operational disruption to the operator while still preventing battery deterioration, maintaining both reliability and ease of operation.
3Loss of information
If a warning signal is provided when electrolyte level is low, then the operator is alerted, but the warning may be overlooked in noisy warehouse environments
Solution Approach 1:
The patent replaces the acoustic warning system with an electronic control system that directly adjusts motor output. Instead of relying on sound signals that can be overlooked in noisy environments, the system uses electrical control to modify vehicle operation, ensuring the operator perceives the condition through actual vehicle performance changes rather than potentially missed auditory warnings.
Solution Approach 2:
The system implements feedback by continuously monitoring electrolyte level and immediately reflecting this information through motor output adjustments. The operator receives real-time feedback about battery condition through vehicle performance changes, ensuring awareness without relying on external warning signals that can be overlooked in noisy warehouse environments.
4Reliability
If the motor output is limited gradually based on vehicle operating time with lowered electrolyte level, then battery deterioration is prevented, but the vehicle performance is reduced
Solution Approach 1:
The system applies dynamics by making motor output dynamically adjustable based on electrolyte level and operating time. Rather than fixed power limitation, the motor controller continuously adapts output to match battery capacity, extending battery life while minimizing performance reduction. The vehicle maintains adequate power for essential operations without causing battery deterioration.
Solution Approach 2:
The system applies partial action by limiting motor output only to the extent necessary to prevent battery deterioration, rather than completely restricting power. This allows the vehicle to maintain sufficient performance for operational needs while still protecting the battery, achieving a balance between reliability and power output.
Data Source
AI summary
An industrial vehicle having a vehicle body includes a battery, an electric motor, an electrolyte level sensor, a vehicle operating with lowered electrolyte level, a vehicle operating time calculator, a data-storing device storing data of the vehicle operating time, an electric motor limiting condition and a motor controller. The electric motor is driven to generate torque. The electrolyte level sensor detects whether or not electrolyte level of the battery is lower than a predetermined level. The vehicle operating time is a time elapsing while the electrolyte level is lower than the predetermined level. The vehicle operating time calculator counts the vehicle operating time in accordance with the detection of the electrolyte level. The electric motor limiting condition limits operation of the electric motor gradually in accordance with the vehicle operating time. The motor controller controls operation of the electric motor based on the electric motor limiting condition.