Integrated Battery Cell Voltage Detection Circuit
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Solution Overview
Problem
Existing car battery systems with series-connected battery cells face challenges in precise voltage detection due to high line impedance variations in long wire-harnesses, leading to potential over-discharge or over-charge of cells, increased manufacturing costs, and risks of malfunction, smoke, or fire from open or short circuits.
Innovation Solution
A car battery system with battery blocks and integrated circuit boards that connect directly to battery cell terminals, minimizing line impedance and preventing short circuits by eliminating the need for long wire-harnesses, ensuring stable and precise voltage measurement and safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wire-harnesses with long wire-leads are used to connect battery cells to the detection circuit, then the detection circuit can be disposed outside the battery block, but the line impedance becomes high and non-uniform, reducing voltage measurement precision
Solution Approach 1:
The detection circuit is integrated directly into the battery block structure, merging the detection function with the battery assembly. This eliminates the need for external wire-harnesses and long wire-leads, thereby reducing line impedance and ensuring uniform electrical connection paths to all battery cells for precise voltage measurement.
Solution Approach 2:
The detection circuit is extracted from the external environment and embedded within the battery block itself. This repositioning removes the harmful element of long wire-leads while maintaining the detection function, achieving both compact integration and measurement precision.
2Adaptability or versatility
If wire-harnesses with long wire-leads are used, then connection flexibility is improved, but impedance variations cause detection errors and reliability decreases
Solution Approach 1:
The detection circuit is merged with the battery block structure, creating a unified assembly where all battery cells are connected through standardized, short electrical paths. This integration ensures uniform impedance characteristics and eliminates the reliability issues associated with varying wire-harness lengths.
3Ease of manufacture
If bundled wire-leads are used in wire-harnesses, then installation is simplified, but open circuits and short circuits can occur causing malfunction, smoke, or fire
Solution Approach 1:
The wire-harness system is extracted and replaced by direct electrical connections integrated into the battery block. This eliminates the bundled wire-leads that pose fire and malfunction risks, while maintaining assembly simplicity through the unified block structure.
Solution Approach 2:
The battery block itself serves as an intermediary structure that provides integrated electrical connections between battery cells and the detection circuit. This eliminates the need for separate wire-harnesses and removes the harmful effects of bundled wires while maintaining electrical connectivity.
4Power
If many battery cells are connected in series to increase output voltage, then system power is improved, but manufacturing cost increases and system lifetime becomes critical
Solution Approach 1:
The detection circuit is merged with the battery block structure, creating a unified assembly that reduces the number of separate components and connections required. This integration simplifies manufacturing processes and reduces assembly complexity for multi-cell series configurations, thereby lowering manufacturing costs while maintaining the high voltage output capability.
Data Source
AI summary
A car battery system includes a plurality of battery cells, each battery cell having a positive electrode terminal and a negative electrode terminal, a battery block that retains the plurality of battery cells in a stacked configuration and has a terminal surface that is formed by battery cell terminal surfaces established by the positive and negative electrode terminals, and a battery state detection circuit that is connected to the electrode terminals of each battery cell to detect the condition of each battery cell. The positive and negative electrode terminals of each battery cell are connected to a circuit board and to the battery state detection circuit. The circuit board is connected to the positive and negative electrode terminals of each battery cell via voltage detection lines, and the voltage detection lines are connected to the same locations on the electrode terminals of each battery cell.