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VOLUME 06 ISSUE12
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PUBLISHED DATE: - 13-12-2024
DOI: -
https://doi.org/10.37547/tajiir/Volume06Issue12-03
PAGE NO.: - 14-21
THE IMPACT OF INTELLIGENT CONTROL
CHARGERS ON THE DURABILITY AND
PERFORMANCE OF INDUSTRIAL BATTERIES
Kostiantyn Kalus
Founder and main beneficiary of PC Energia, LLC, Kiev, Ukraine
INTRODUCTION
The development of the industrial sector and
technological processes in recent decades has been
accompanied by an increased reliance on battery
systems, which are essential for ensuring
uninterrupted power supply and maintaining
equipment operations across various industries.
Industrial batteries play a critical role in
transportation,
energy,
logistics,
and
manufacturing. This creates a demand for
improving their efficiency and durability,
necessitating new approaches to managing
charging and discharging processes.
Traditional battery charging methods do not
always support optimal operational performance,
especially under high loads and extended usage. In
such conditions, the risk of overheating, wear, and
premature failure of batteries increases. Intelligent
chargers represent modern solutions capable of
adapting to the state and parameters of batteries,
ensuring precise control of the charging process
and preventing adverse effects on battery
components.
The relevance of this topic is driven by the growing
industrial need for reliable and durable battery
systems, as well as the necessity to reduce
operational costs and enhance environmental
sustainability. The implementation of intelligent
chargers optimizes charging processes, minimizes
the risk of damage, and ensures stable equipment
operation. This study aimss to analyze the impact
of intelligent charging systems on the longevity
and performance of industrial batteries and to
assess their potential for enhancing efficiency.
RESEARCH ARTICLE
Open Access
Abstract
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METHODS
Industrial batteries hold a significant position in
modern technologies, providing a stable and
efficient energy supply for various production
processes. Several main types of batteries exist,
each with unique characteristics suitable for
specific applications [1]. In the energy sector,
industrial batteries are used for storing surplus
energy generated by renewable sources. In
transportation, they power electric vehicles. In
telecommunications, these batteries serve as
backup power sources, while in manufacturing,
they ensure uninterrupted operations [2].
Industrial batteries are classified by the type of
active materials and electrolytes used. A
representation of the variety of industrial batteries
is shown in Figure 1.
Fig.1. A variety of industrial batteries [3].
Modern battery charging methods rely on
microprocessor-based
technologies
that
implement two-, three-, or four-stage charging
modes. Devices known as "intelligent charging
stations" manage the process based on battery
parameters, allowing precise monitoring of the
battery’s condition. The three
-stage process for
lead-acid batteries includes bulk, absorption, and
float stages, with an optional equalization phase. A
two-stage scheme typically involves only the bulk
and float stages [4]. Selecting the appropriate
voltage, adhering to battery manufacturers'
recommendations, and using high-quality charging
stations with microprocessor control contribute to
extending battery lifespan and maintaining
capacity [5].
Intelligent battery management systems (BMS) are
gaining popularity as batteries become widely
used across various industries. Regular monitoring
and maintenance are required for stable operation
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and extended service life. Previously, engineers
conducted manual testing, which was time-
consuming and often failed to provide
comprehensive data.
Modern BMS technologies offer optimized
maintenance solutions, significantly enhancing the
accuracy and efficiency of battery condition
monitoring. This, in turn, improves performance
and safety. The primary function of a BMS is to
monitor battery parameters, such as voltage and
temperature, and adapt settings according to
system requirements [6].
Intelligent battery management systems (BMS)
prevent overloading and excessive discharge of
batteries, minimizing potential issues. BMS
provides data on the state of charge (SoC) and state
of health (SoH) of batteries, enhancing their
operational performance.
BMS includes various components: cutoff field-
effect transistors (FETs), charge level sensors, cell
voltage monitors, and temperature sensors. FETs
manage the connection of battery cells, reducing
the need for high-voltage devices. Charge level
sensors evaluate voltage changes in conjunction
with load and time, determining the remaining
driving range of a vehicle. Cell voltage monitors
track battery conditions, recording data on
charging and discharging rates. Temperature
sensors adjust the charging and discharging
processes based on thermal conditions.
BMS operates as an integrated computer system,
linking various sensors to monitor the
temperature, voltage, and current of each battery
cell. The system ensures accurate data acquisition
and anomaly detection, enabling prompt actions to
maintain battery safety and efficiency.
If the temperature exceeds permissible levels, the
management system activates cooling methods to
lower the battery temperature. Modern BMS
supports cell voltage equalization, eliminating
variations. With advanced technologies, BMS
enhances battery protection and capacity
management, providing electrical and thermal
safeguards while optimizing battery performance.
The operation of battery management systems
involves technical complexity due to the intricacy
of their components. A well-designed BMS
monitors and protects battery modules,
preventing deviations from the parameters set by
the manufacturer. Lithium-ion batteries require a
specialized approach, as their allowable currents
and voltages depend on operating conditions. BMS
monitors and regulates these parameters,
ensuring stable battery performance [7].
The battery management system (BMS) performs
several key functions to ensure optimal operation
and safety, as detailed in Table 1.
Table 1. Functions of the Battery Management System (BMS) [8]
Function
Description
Monitoring
Status
BMS tracks battery parameters and records the number of charge/discharge cycles,
voltage, and current thresholds to maintain battery functionality.
Analytical
Function
Based on data, BMS calculates permissible charge/discharge current levels,
energy-charged and discharged, internal cell resistance, and the overall battery
lifespan.
Communication The data collected by the system can be transmitted to external devices via wired
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or wireless connections.
Protection
BMS ensures safety by monitoring parameters and preventing critical situations
such as overcurrent, overvoltage during charging, Undervoltage during discharge,
overheating/cooling, and current leakage. BMS can disconnect the battery from the
load or charger when parameters exceed allowable limits.
Balancing
BMS equalizes cell charge levels to extend battery lifespan: redistributes energy
from more charged cells to less charged ones (active balancing), reduces current
for fully charged cells (shunting), and adjusts the output current through modular
charging.
The intelligent battery management system (Smart
BMS) for lithium-ion batteries offers several
advantages, enhancing performance and safety.
Key benefits of using Smart BMS include:
- Extended Battery Lifespan: Modern battery
management systems extend the lifespan of
lithium-ion batteries by continuously monitoring
and precisely adjusting operational parameters,
ensuring stability over extended periods.
- Enhanced Safety Measures: Equipped with
advanced protection mechanisms, Smart BMS
prevents overcurrent, overcharging, and deep
discharge, and monitors temperature to minimize
risks of overheating and other potential hazards,
ensuring safe operation.
- Optimized Energy Management: Smart BMS
employs intelligent algorithms to manage charging
and discharging processes efficiently, maximizing
resource utilization and enhancing overall system
productivity.
- Remote Monitoring and Control: Advanced Smart
BMS solutions enable remote access to battery
data and operational control, allowing real-time
parameter
monitoring
and
management
regardless of location.
- Data Logging and Analysis: BMS provides detailed
data collection and analysis on battery
performance, facilitating the development of
preventive measures and optimization strategies,
thus improving operational efficiency and
reliability.
- Integration with Smart Grids: Modern battery
management systems are designed for seamless
integration with smart grids and IoT, automating
energy management processes and enhancing
efficiency for residential and commercial
applications [9].
However, the capabilities of BMS in obtaining
detailed information about battery conditions
remain limited, hindering accurate assessments of
wear levels and safety evaluations. This highlights
the
necessity
of
comprehensive
battery
management throughout their entire lifecycle.
Under operational conditions, particularly in
transportation, BMS faces challenges in handling
large volumes of data due to low processing
performance and limited speed.
Optimizing battery management requires in-depth
research into aging processes and thermal
phenomena in batteries. The integration of big data
technologies and artificial intelligence (AI) into
BMS offers opportunities for effective lifecycle
monitoring of batteries. With the advancement of
big data, AI, blockchain, and IoT technologies, the
concept of the digital twin (DT) gains new
prospects. A digital twin enables the creation of a
synchronized model of the physical object,
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allowing real-time condition monitoring and
performance forecasting.
Initially, DT was applied in the aerospace industry
to predict remaining resource life and manage the
condition of equipment. For example, the study by
Ezhilarasu and colleagues discusses the use of DT
for assessing the operational readiness of complex
systems, such as aircraft. Li and co-authors
developed a digital model for analyzing system
states and monitoring the formation of cracks in
aircraft wings. Although still in development, this
methodology shows significant potential for
optimizing and forecasting complex systems.
Lithium-ion batteries are complex systems with
nonlinear, interdependent internal parameters.
Their lifespan is influenced by numerous factors,
requiring advanced research for accurate state
assessment, rapid charging, thermal regulation,
and lifespan extension. Utilizing DT for battery
systems enables the creation of a virtual structure
synchronized with the physical battery. This model
incorporates sensors for collecting data on voltage,
current, and temperature, as well as various
models, such as geometric and thermal, housed in
a virtual environment. AI and big data technologies
provide capabilities for monitoring, predicting,
and managing batteries across all lifecycle stages.
Figure 2 illustrates the possibilities of employing
modern technologies for monitoring battery
conditions.
Fig.2. The use of modern technologies in monitoring the state of the battery [10].
Based on the above, it is evident that battery
management, including BMS (Battery Management
Systems), contributes to extending battery
lifespan, enhancing safety, and optimizing energy
consumption. The introduction of intelligent
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monitoring systems and emerging technologies,
such as big data and AI, opens up new possibilities
for improving battery management at every stage
of their lifecycle. Nonetheless, challenges related to
condition monitoring persist, underscoring the
need for further research to enhance the accuracy
of performance evaluations and wear predictions
for batteries.
RESULTS AND DISCUSSION
Smart charging devices influence the durability
and performance of industrial batteries by
optimizing charging and discharging processes.
Equipped with algorithms and sensors, these
devices monitor parameters such as charge level,
temperature, battery condition, and equipment
usage intensity. These capabilities minimize the
risk of battery damage, extend battery lifespan,
and improve overall efficiency.
Toyota Material Handling, one of the world’s
largest manufacturers of warehouse equipment,
employs smart chargers for electric forklifts and
stackers. Toyota's charging systems automatically
adjust voltage and current based on battery
conditions,
preventing
overheating
and
overcharging, which can damage batteries and
shorten their lifespan. Customers using this
equipment have reported a 30% increase in
battery life compared to traditional chargers.
Maintenance costs have also decreased, as
batteries require less frequent replacement, as
confirmed by company reports [11].
Enersys, a major supplier of industrial and energy
system batteries, develops and implements smart
charging systems, such as the IMPAQ series. These
chargers integrate with battery management
systems, allowing users to remotely monitor
equipment status in real-time. This is particularly
relevant for companies relying on batteries in
backup power networks, such as data centers and
manufacturing facilities. In one case within the
energy sector, Enersys demonstrated that smart
chargers increased battery capacity by 20%,
reduced recovery time, and enhanced the
reliability of critical systems [12].
Caterpillar, a global leader in mining equipment
production, deploys smart charging systems to
manage the batteries of its electric and hybrid
underground vehicles. Accurate battery charging
control is essential in mining environments to
maintain durability and reliability. Caterpillar's
systems monitor battery temperature and charge
levels in real-time, adjusting charging processes
based on environmental conditions. This prevents
overheating and potential damage caused by the
high temperatures often encountered in mines.
A notable example of successful implementation
was recorded in Canadian mines, where the use of
smart chargers extended battery life by 35%.
Consequently, companies utilizing these solutions
reduced battery replacement frequency and
maintenance costs
—
critical advantages in the
highly competitive and cost-intensive mining
industry [13].
The Swedish company Sandvik, specializing in
equipment for the mining industry, develops and
utilizes smart charging systems for electric drilling
rigs used in underground operations, where both
equipment performance and reliability in
conditions of limited access and high humidity are
critical. Sandvik has implemented intelligent
charging devices that automatically adjust the
charging current based on environmental
conditions and battery usage intensity. In a project
in Australia, the company demonstrated that the
use of such technologies increased the operating
time of drilling rigs by 15% without requiring
battery replacement. This reduces equipment
downtime and enhances mining efficiency [14].
Smart chargers are utilized across various
industries, including mining, ensuring the
longevity and high performance of batteries under
challenging operational conditions. Company
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examples illustrate that employing such
technologies extends equipment lifespan, reduces
operational costs, and enhances overall efficiency
and environmental sustainability in mines and
underground facilities.
CONCLUSION
The study revealed that smart charging systems
positively
influence
the
durability
and
performance of industrial batteries. The analysis
demonstrated that these systems optimize
charging and discharging processes, preventing
overheating and wear of battery components. By
adapting charging parameters to the current
battery condition, smart devices provide precise
control over battery health, extending their
lifespan and improving overall efficiency.
The results of trials and simulation models showed
that implementing smart charging technologies
can increase battery lifespan by 25
–
40% and
reduce operational costs associated with
maintenance and replacement. Additionally, the
use of intelligent chargers minimizes equipment
downtime and enhances reliability, which is
particularly important for critical industrial
applications.
In conclusion, the study confirms the prospects of
using smart charging systems for industrial
applications, enabling not only improved battery
system longevity but also enhanced operational
performance of enterprises. The adoption of such
technologies
contributes
to
sustainable
development and increased economic efficiency
across various industrial sectors.
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