Battery Connection Temperature Differential Failure Detection
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Solution Overview
Problem
Existing battery safety systems lack predictive capabilities to detect unhealthy connections before they reach catastrophic failure, relying on single temperature thresholds that may not prevent fires effectively.
Innovation Solution
A system comprising current sensors and multiple temperature sensors to monitor battery packs, allowing for the detection of degraded connections by comparing cell and connection temperatures, enabling early identification of potential failures under varying loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If single temperature threshold sensors are used to detect battery failures, then the system complexity is low, but the detection precision and reliability are insufficient to predict connection failures before catastrophic events
Solution Approach 1:
The patent divides the temperature monitoring system into multiple segments: at least one temperature sensor on the cell body and at least one temperature sensor near the cell connections. This segmentation allows independent monitoring of different thermal zones, enabling precise detection of connection failures through temperature differential comparison while maintaining manageable system complexity through modular sensor placement
Solution Approach 2:
The patent introduces temperature differential (ΔT) as an intermediary parameter that mediates between the raw temperature readings from multiple sensors and the final failure detection decision. By comparing the temperature difference between connection sensors and cell body sensors against a threshold, the system achieves predictive detection without requiring complex multi-parameter analysis
2Reliability
If multiple temperature sensors are deployed to monitor connection temperatures, then the detection reliability improves, but the device complexity and cost increase
Solution Approach 1:
The patent applies local quality by placing temperature sensors specifically at locations most indicative of connection health: on the cell body and near the cell connections. This targeted sensor placement provides high reliability for detecting connection failures through local temperature differentials without requiring comprehensive temperature mapping of the entire battery pack, thus avoiding excessive complexity
3Reliability
If temperature thresholds are set high to accommodate component ratings, then component safety is maintained, but early detection of connection degradation is delayed
Solution Approach 1:
The patent performs preliminary detection by monitoring temperature differentials between connection sensors and cell body sensors before the absolute temperature reaches catastrophic levels. By detecting abnormal heat generation at connections through ΔT comparison early in the degradation process, the system enables preventive action before temperatures approach component rating limits or fire thresholds
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 approach allows for the proactive detection of connection degradation, preventing fires by identifying temperature anomalies before significant heat buildup occurs, thus enhancing battery safety and reliability.
Implementation Method 1
the temperature of the cell connections would be similar to the temperature of the body of each cell... the temperature near the cell connection to rise beyond the levels normally expected
Implementation Method 2
If bolts securing the cells become lose resistance increases... Under high load, when a connection is failing, the resistance of the connection will rise
Implementation Method 3
the resistance of the connection will rise. This increase in resistance will cause the temperature near the cell connection to rise
Data Source
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AI summary
A system and method of detecting battery connection failures relies upon measuring battery cell body temperature and battery connector temperature at a measured current. The difference between these two temperatures is calculated using a software driven comparator. The comparator compares the difference as measured against a predetermined safe difference for the measured current. If the measured value exceeds the predetermined safe value an alarm is given. In one embodiment of the invention the difference between the two temperatures is compared to a predetermined safe difference independent of current measurements.