Traction Battery Arc Test Fixture With Insulated Electrode Gap
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Solution Overview
Problem
Existing test assemblies for evaluating the risk of electrical arcing in traction batteries are large, costly, and often destroyed during testing, making it difficult to interpret results and identify the starting point of electrical arcs, which poses a risk to battery safety and vehicle integrity.
Innovation Solution
A compact, non-conductive holder with electrically conductive electrodes is used to create a controlled electric arc between ends, allowing for precise evaluation of arcing properties by monitoring electric parameters such as resistance, voltage, and current, adaptable to different gap widths and environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If large test assemblies are used to evaluate electrical arcing risk, then the evaluation can be performed with instrumented battery packs, but the test assemblies require large space and are often destroyed during testing, making results difficult to interpret
Solution Approach 1:
The patent extracts the essential testing function from complex instrumented battery packs by using a simplified test assembly with electrodes and holder that can be inserted into the battery pack. This extraction allows evaluation of electrical arcing properties without requiring the entire battery pack structure, reducing space requirements while maintaining measurement capability
Solution Approach 2:
The patent creates a simplified model (test assembly) that copies the essential electrical arcing evaluation function without replicating the full complexity of instrumented battery packs. The test assembly uses electrodes and holder to simulate arcing conditions, providing a scalable solution that maintains evaluation accuracy while reducing device complexity
2Reliability
If conventional test assemblies are used, then electrical arcing can be tested, but the assemblies are often destroyed during testing with uncontrolled damage spread across components, making it difficult to identify the starting point of electrical arcs
Solution Approach 1:
The patent introduces a non-conductive holder as an intermediary component that supports the electrodes and provides electrical isolation. This holder acts as a mediator that prevents uncontrolled damage spread by containing the electrical arcing between the electrodes, while the non-conductive material protects surrounding components from damage
Solution Approach 2:
The patent applies local quality by making only the electrode tips conductive while the holder remains non-conductive. This localized conductivity concentration allows electrical arcing to occur only at specific points between electrode tips, enabling precise identification of arc starting points while preventing damage to other components
3Measurement precision
If instrumented battery packs are used for testing, then comprehensive electrical properties can be monitored, but the cost increases and the setup becomes more complex
Solution Approach 1:
The patent segments the testing function into separate components: a non-conductive holder, conductive electrodes, and connection means. This segmentation allows each component to be manufactured independently using appropriate materials and processes, reducing overall manufacturing cost while maintaining the capability to monitor electrical parameters during testing
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
The solution enables precise, cost-effective, and repeatable evaluation of arcing properties in traction batteries, reducing damage and providing valuable insights without requiring a full vehicle setup, thus enhancing safety and efficiency in testing.
Implementation Method 1
the first electrode and the second electrode are configured to conduct an electric current... an electric arc may occur between the first end of the first electrode and the first end of the second electrode
Implementation Method 2
an electrically non-conductive or electrically insulated holder... The non-conductive or electrically insulated property of the holder may be achieved by using materials with these properties as holder and/or coating and/or alike
Data Source
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AI summary
The disclosure relates to a test device (22) for evaluating an electric arcing property of a traction battery (12) of a vehicle. The test device (22) comprises an electrically nonconductive or electrically insulated holder (30), a first electrode, and a second electrode. The first electrode has a first end and a second end. The second electrode has a first end and a second end. The first electrode and the second electrode are supported on the holder (30) such that the first ends form a gap between each other. Additionally, a test system (14) for evaluating an electric arcing property of a traction battery (12) of a vehicle is described. The test system (14) comprises such a test device (22), an electric source (24), and an electric monitoring unit (26). Furthermore, a use of a test device (22) and/or a use of a test system (14) are shown. Additionally, a method for evaluating an electric arcing property of a traction battery (12) of a vehicle is presented.