Battery Cell Monitoring Circuit for Serviceable Series Modules
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Solution Overview
Problem
Existing vehicle battery module designs are hazardous to handle during service or adverse events, require specialized training and equipment, and suffer from energy loss and degradation due to parallel cell connections, making them impractical for high-performance vehicles.
Innovation Solution
A battery module design with series-connected cells isolated from the enclosure, featuring a printed circuit board assembly (PCBA) with cell monitoring and conditioning circuits, relays, and a separate external interface PCBA, allowing safe handling and easy service without specialized equipment, while minimizing fire risk and energy loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If groups of cells are connected in parallel to achieve desired current capability, then current capability is improved, but energy loss and degradation increase
Solution Approach 1:
The patent divides the battery system into individual cell modules, each with its own monitoring circuit, rather than connecting groups of cells in parallel. This segmentation allows each cell to be managed independently, eliminating the energy loss and degradation issues associated with parallel connections while maintaining the desired current capability through proper series configuration.
2Ease of manufacture
If safety devices are external to modules and shared by all modules, then cost and manufacturing complexity are reduced, but safety and reliability are compromised
Solution Approach 1:
The patent integrates safety devices and monitoring circuits directly within each battery module, creating a nested structure where each module contains its own protective elements. This ensures that each module is inherently safe and reliable while maintaining manufacturing efficiency through standardized module design.
3Ease of operation
If external terminals are always connected to cells with large current capability, then ease of connection is improved, but fire risk and injury risk increase
Solution Approach 1:
The patent introduces protective circuitry and monitoring systems as intermediaries between the external terminals and the battery cells. These intermediaries manage the connection safely, controlling current flow and detecting anomalies, thereby maintaining ease of connection while eliminating the fire and injury risks associated with always-connected high-current terminals.
4Ease of manufacture
If a monolithic non-serviceable battery pack is used, then manufacturing simplicity is improved, but serviceability and repairability are lost
Solution Approach 1:
The patent divides the battery pack into modular, serviceable units that can be independently replaced or repaired. Each module is designed as a discrete component with standardized interfaces, allowing technicians to service individual modules without specialized equipment while maintaining manufacturing simplicity through modular assembly.
Data Source
AI summary
A battery cell monitoring and conditioning circuit is disclosed to facilitate low cost manufacture of battery modules comprising a plurality of series connected cells. A battery management system utilizing a plurality of series connected cell monitoring and conditioning circuits is disclosed. Methods are provided for operating the disclosed circuits.