Battery Contact Failure Detection for Low-Resistance Connection Faults
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Solution Overview
Problem
High-voltage batteries face challenges in detecting contact failures among busbars, contactors, fuses, and cells, especially when contact resistance is low or instantaneous currents flow, leading to difficulties in early detection of secondary failures such as melting of contact portions or sudden output loss.
Innovation Solution
A battery contact failure detecting device and method that utilize a sensor to measure current and voltage of battery cells and a processor to count abnormal occurrences based on these measurements, detecting contact failures due to short circuits or open circuits in the connecting parts, and restricting battery use when predetermined thresholds are exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional voltage monitoring is used to detect contact failures, then over voltage or under voltage can be recognized, but contact failures with small contact resistance (smaller than several mΩ) cannot be detected easily
Solution Approach 1:
The patent changes the detection parameter from voltage alone to a combination of voltage and current parameters. By monitoring both voltage and current simultaneously, the system can detect contact resistance changes even when they are small (smaller than several mΩ), overcoming the limitation of conventional voltage-only monitoring methods.
Solution Approach 2:
The patent replaces the conventional voltage-based detection mechanism with an enhanced electrical parameter analysis mechanism that incorporates current measurement. This substitution enables the detection of subtle contact resistance changes that were previously undetectable through voltage monitoring alone.
2Speed
If instantaneous current monitoring is used, then current flow can be detected, but contact failures occurring for time smaller than mature time cannot be detected easily
Solution Approach 1:
The patent implements preliminary action by continuously monitoring both voltage and current parameters before a contact failure fully develops. The system analyzes the relationship between voltage and current in real-time, enabling detection of contact failures even when they occur for time periods smaller than the mature detection time, thus improving both detection speed and reliability.
Solution Approach 2:
The patent employs feedback mechanisms by continuously analyzing the relationship between measured voltage and current. The system uses the correlation between these parameters to detect contact failures in real-time, providing immediate feedback when abnormal contact resistance is detected, even for instantaneous failures.
3Reliability
If contact failure detection is improved for low resistance and instantaneous failures, then early detection of secondary failures is achieved, but the complexity of the detection system increases
Solution Approach 1:
The patent achieves multi-functionality by using a single detection system that monitors both voltage and current parameters simultaneously. This unified approach enables the system to detect various types of contact failures (low resistance, instantaneous, and complete open circuits) without requiring separate detection mechanisms for each failure mode, thus improving reliability while controlling complexity.
Solution Approach 2:
The patent merges voltage monitoring and current monitoring into a single integrated detection system. By combining these two measurement functions and analyzing their relationship, the system achieves comprehensive contact failure detection capability without the need for multiple separate detection systems, thereby improving reliability while minimizing the increase in device complexity.
Data Source
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AI summary
A battery contact failure detecting device (200) according to the present invention includes a battery module (100, 210) formed of a plurality of battery cells (10, 10a, 10b); a connecting part (220) including at least one of a busbar, a contactor, and a fuse and connects the battery cells (10, 10a, 10b) to each other; a sensor (230) configured to measure a current and a voltage of each of the battery cells (10, 10a, 10b); and a processor (240) configured to count a number of abnormal occurrences on the basis of the current and the voltage measured by the sensor (230) to detect a contact failure of the battery cells (10, 10a, 10b) due to a short circuit or open circuit of the connecting part (220).