Battery Connection Quality Evaluation System
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Solution Overview
Problem
Existing methods for evaluating battery connection quality in vehicle battery assemblies are inadequate, as they rely on visual and mechanical inspections which may not accurately assess the electrical integrity of welded tab connections, potentially leading to performance issues.
Innovation Solution
A system comprising a battery testing unit with a housing and multiple testing modules that communicate electrically with battery modules, using a controller to evaluate voltage and resistance measurements, and spring-loaded pins to ensure reliable contact, allowing for simultaneous determination of electrical connection quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual and mechanical inspection methods are used to evaluate battery connection quality, then the inspection process is simple and quick, but the accuracy of electrical integrity assessment is insufficient
Solution Approach 1:
The patent replaces visual and mechanical inspection methods with an electrical measurement system that uses voltage and resistance measurements to assess connection quality. The testing unit applies voltage across the battery module and measures the resulting current to calculate resistance, providing an electrical-based evaluation method that is more accurate for assessing electrical integrity than mechanical inspection.
Solution Approach 2:
The patent introduces a testing unit with spring-loaded pins as an intermediary device between the inspection system and the battery module. This intermediary establishes reliable electrical contact points through the spring-loaded mechanism, enabling accurate voltage and resistance measurements without requiring direct complex instrumentation on the battery cells themselves.
2Reliability
If electrical measurement methods are implemented to accurately assess connection quality, then measurement accuracy improves, but the testing system becomes more complex
Solution Approach 1:
The patent divides the testing system into modular components: a testing unit with spring-loaded pins for contact, a controller for measurement and analysis, and a display for results. This segmentation allows the complex electrical measurement functionality to be distributed across separate modules, making the system more manageable and easier to implement while maintaining high reliability through specialized functions in each module.
Solution Approach 2:
The spring-loaded pins automatically establish and maintain electrical contact through their mechanical spring mechanism, which self-adjusts to ensure reliable connection without requiring manual intervention or complex positioning systems. This self-service feature simplifies the overall system complexity while ensuring consistent measurement reliability.
3Reliability
If spring-loaded pins are used to ensure reliable contact, then electrical connection reliability improves, but the device structure becomes more complex
Solution Approach 1:
The patent extracts the contact-making function into a separate spring-loaded pin mechanism that is independent from the measurement and control electronics. This extraction allows the contact reliability issue to be solved mechanically through the spring-loaded design, while the electrical measurement functions remain separate in the controller, reducing overall system complexity through functional separation.
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
This system provides accurate and reliable assessments of battery connection quality, identifying both acceptable and unacceptable connections, thereby ensuring consistent battery performance and facilitating quality control in manufacturing.
Implementation Method 1
at least one spring loaded pin extending from the lower surface of the body of each of the plurality of testing modules to releasably engage and electrically connect the battery testing unit with an interconnecting board
Implementation Method 2
The controller is in communication with the at least one element and at least one contact to simultaneously evaluate voltage and resistance measurements of the one or more battery modules
Implementation Method 3
the controller to perform one or more determinations of electrical connection quality of the one or more battery modules... simultaneously evaluate voltage and resistance measurements
Data Source
AI summary
A system for evaluating battery connection quality in one or more battery modules of a battery assembly includes a battery testing unit having a housing including an upper surface and a lower surface. A plurality of testing modules are disposed on the lower surface of the housing to communicate with and electrically contact the one or more battery modules of the battery assembly. The plurality of testing modules each include at least one connector extending from a lower surface of the testing module and at least one contact disposed on one or more side surfaces of the testing module. A controller is in electrical communication with the at least one connector and at least one contacts to simultaneously evaluate voltage and resistance measurements of the one or more battery modules of the battery assembly.