Battery Disconnection Unit Layout for Automatic Module Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing battery systems require a manual safety disconnector to ensure safety during disassembly and maintenance, which increases costs, volume, and complexity due to the need for manual intervention.
Innovation Solution
A battery system design that eliminates the manual safety disconnector by using a battery disconnection unit (BDU) with a first main switch, precharge switch, and current sensor, controlled by a battery management unit to automatically separate battery modules, reducing the need for manual intervention and enhancing safety and convenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a manual safety disconnector (MSD) is used to ensure safety during disassembly and maintenance, then safety is improved, but manufacturing cost, device volume, and system complexity increase
Solution Approach 1:
The patent combines the MSD function with the existing BDU components (main switch, precharge switch, current sensor) into a single integrated system. The BDU's main switch serves dual purposes: normal operation disconnection and safety disconnection during maintenance, eliminating the need for a separate MSD component and reducing system complexity while maintaining safety
Solution Approach 2:
The main switch in the BDU is designed to perform multiple functions: it operates as a normal disconnect switch during battery module operation and simultaneously serves as a safety disconnector during maintenance. This multi-functional design eliminates the need for dedicated MSD hardware, reducing cost and complexity while ensuring safety
2Reliability
If a manual safety disconnector (MSD) is used to ensure safety during disassembly and maintenance, then safety is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the MSD functionality into the existing BDU component structure, eliminating the need for separate MSD hardware. This integration reduces component count, material costs, and assembly complexity, thereby lowering manufacturing costs while maintaining safety functionality
Solution Approach 2:
The main switch is designed as a universal component that performs both normal operational disconnection and safety disconnection functions. This eliminates the need for duplicate safety disconnector hardware, reducing manufacturing costs through component consolidation
3Reliability
If a manual safety disconnector (MSD) is used to ensure safety during disassembly and maintenance, then safety is improved, but device volume increases
Solution Approach 1:
The patent integrates the safety disconnector function within the existing BDU component footprint. By making the main switch serve dual purposes (normal operation and safety disconnection), no additional volume is required for separate MSD hardware, thereby reducing overall device volume while maintaining safety
4Reliability
If a manual safety disconnector (MSD) is used, then safety during disassembly is improved, but the need for manual intervention increases operational complexity
Solution Approach 1:
The system provides self-service safety protection through automatic overcurrent detection and disconnection. The current sensor continuously monitors for abnormal conditions (overcurrent, inrush current) and automatically triggers the main switch to disconnect, eliminating the need for manual safety interventions while maintaining safety
Solution Approach 2:
The current sensor provides continuous feedback on electrical conditions to the control logic. When abnormal conditions are detected (overcurrent or inrush current), the system automatically responds by disconnecting the main switch, creating a closed-loop safety system that operates without manual intervention
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 reduces manufacturing costs, complexity, and volume by automating the disconnection process, enhancing operational convenience and safety without the need for a manual safety disconnector, while maintaining effective protection against overcurrent and inrush currents.
Implementation Method 1
a precharge switch and a precharge resistor connected in parallel with the first main switch and connected in series with each other
Implementation Method 2
a current sensor CS arranged on a low voltage path, i.e., a path between the second battery module 120 and a second battery terminal B-
Data Source
Figure 1
Figure 2
AI summary
A battery system includes a first battery module including a plurality of first battery cells, a second battery module including a plurality of second battery cells, and a battery disconnection unit (BDU) connected between the first battery module and the second battery module. The battery disconnection unit (BDU) includes a first main switch connected in series between the plurality of first battery cells and the plurality of second battery cells, and a precharge switch and a precharge resistor connected in parallel with the first main switch and connected in series with each other.