Battery Contact Quality Classification via Temperature Sensing
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Solution Overview
Problem
Electric and hybrid vehicles require reliable monitoring of electrical contact quality between battery and load connections to prevent voltage drops and overheating, as conventional methods fail to detect increased contact resistance early enough.
Innovation Solution
An apparatus with a temperature sensor and control device that classifies contact quality by monitoring temperature, reducing current flow when excessive temperatures are detected to prevent overheating and voltage drops, and integrates this functionality into battery and receiving systems for comprehensive diagnosis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature monitoring is implemented to detect poor contact quality, then reliability of contact quality detection is improved, but device complexity increases due to additional sensors and control systems
Solution Approach 1:
The electrical connection element performs its own temperature monitoring through an integrated temperature sensor, eliminating the need for separate external monitoring systems. The connection element itself generates and processes the temperature data needed to assess contact quality, making the system self-diagnosing and reducing overall system complexity.
Solution Approach 2:
The temperature sensor is integrated directly into the electrical connection element, merging the monitoring function with the connection function. This consolidation reduces the number of separate components and simplifies the system architecture while maintaining reliable contact quality detection.
2Temperature
If current flow is reduced to prevent overheating, then temperature control is improved, but power delivery capability deteriorates
Solution Approach 1:
The control device continuously monitors temperature data from the sensor and uses this feedback to dynamically adjust current flow. When temperature exceeds thresholds, the control device reduces current; when temperature is acceptable, normal current flow is restored. This closed-loop control ensures temperature management without permanently limiting power delivery capability.
Solution Approach 2:
The system dynamically adjusts current flow based on real-time temperature conditions rather than using a fixed current limit. This dynamic control allows the system to deliver full power when safe and reduce power only when necessary to prevent overheating, optimizing both temperature control and power delivery.
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
The solution effectively prevents undesirable voltage drops and overheating by reducing current flow when poor contact quality is detected, ensuring reliable operation and extending the lifespan of electrical connections.
Implementation Method 1
a temperature sensor for sensing the temperature of the first connection element and/or of the second connection element
Implementation Method 2
when current is drawn from the battery a voltage drop occurs between the two connection elements which, together with the present current intensity, determines a dissipative power which is introduced into the contact region and which increases the temperature of the first connection element and/or of the second connection element further
Data Source
AI summary
A device for classifying electrical contacting between a first connecting element of a battery and a second connecting element, which is directly or indirectly connected to an electrical load. A temperature sensor is provided for detecting the temperature of the first connecting element and/or of the second connecting element and a control device, which is coupled to the temperature sensor and which is configured, on the basis of a detecting signal of the temperature sensor, to classify the electrical contacting between the first connecting element and the second connecting element. A corresponding method and to a battery system, as well as a battery receiving system including such a device for classifying electrical contacting. Moreover, there is provided an electrical power supply system with such a battery system and such a battery receiving system.