Battery Cell Contact Testing Using 3D Field Sensor Scanning
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Solution Overview
Problem
The existing methods for testing the electrical connections in battery modules are time-consuming and prone to errors due to the need for precise positioning of contact electrodes, which is challenging because of manufacturing variations, and can result in incorrect results from electrode wear or contamination.
Innovation Solution
A test apparatus with a sensor positioning system that moves in three dimensions to automate the testing of multiple contact points simultaneously, using field sensors to detect magnetic or electric fields generated by battery cell current, allowing for contactless evaluation of connection quality without the need for individual resistance measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If resistance measurement with contact electrodes is used to test cell contacts, then electrical conductivity can be determined, but testing time increases and positioning precision requirements increase due to individual testing of each contact point
Solution Approach 1:
The patent combines multiple contact point measurements into a single integrated measurement process. By connecting multiple battery cells in parallel and using a single sensor to measure the combined magnetic field, the system evaluates multiple contact points simultaneously rather than individually, thereby reducing testing time while maintaining measurement precision.
Solution Approach 2:
The sensor serves multiple functions: it detects magnetic fields generated by current flow, determines contact quality, and evaluates multiple contact points simultaneously. This multi-functional approach eliminates the need for separate measurement processes for each contact point, addressing both precision and time efficiency requirements.
2Measurement precision
If contact electrodes are positioned precisely to test each contact point individually, then accurate resistance measurement is achieved, but the complexity of positioning increases due to manufacturing variations
Solution Approach 1:
The patent replaces the mechanical contact electrode positioning system with a magnetic field-based sensing system. Instead of physically contacting each point and requiring precise mechanical alignment, the system uses magnetic field detection to measure contact quality, thereby reducing positioning complexity while maintaining measurement accuracy.
Solution Approach 2:
The magnetic field acts as an intermediary between the current flow and the sensor measurement. Rather than directly measuring electrical resistance through physical contact, the system measures the magnetic field generated by current flow, which indirectly indicates contact quality. This intermediary approach simplifies the measurement system while preserving measurement precision.
3Reliability
If contact electrodes are pressed against test points to ensure correct positioning, then measurement contact is established, but electrode wear and contamination occur leading to incorrect test results
Solution Approach 1:
The patent replaces the mechanical contact-based measurement system with a non-contact magnetic field sensing system. By eliminating physical contact between electrodes and test points, the system prevents electrode wear and contamination while maintaining reliable measurements through magnetic field detection.
Solution Approach 2:
The patent extracts the measurement function from the physical contact interface and relocates it to the magnetic field domain. By separating the measurement process from direct mechanical contact, the system eliminates the harmful effects of wear and contamination while preserving the ability to reliably assess contact quality.
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 reduces testing time, minimizes the risk of contamination, and provides a more robust and accurate assessment of connection quality by evaluating magnetic or electric fields, enabling simultaneous testing of multiple contact points with less precise positioning requirements.
Implementation Method 1
detecting a magnetic field in the region of the at least one test point, which is generated by the battery cell current
Implementation Method 2
using field sensors to detect magnetic or electric fields generated by battery cell current
Data Source
AI summary
Apparatus (100) and method for testing cell contact of battery cells (102) of a battery module (104), which battery cells are electrically connected in parallel via a contacting system (106, 107). The apparatus includes a sensor positioning system (108) for positioning a sensor device (110) at a plurality of test points (112) of the battery module, which is movable along a longitudinal axis (X), a transverse axis (Y), and a vertical axis (Z), and a current generation circuit (114) for generating a battery cell current (I), which is a discharging current from the battery cell or a charging current into the battery cell. The sensor device includes at least one field sensor (118), which, after the sensor device is positioned at one of the test points, detects a field in the region of the test point, which is generated by the battery cell current generated with the current generation circuit.