Battery Pack Defect Detection Using Frequency Domain Reflectometry

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Solution Overview

Problem

Conventional battery testing methods are expensive, pose safety concerns due to high-voltage and high-power demands, and are inefficient in detecting defects within battery packs, particularly in electric vehicles.

Innovation Solution

A system and method utilizing a probe system with measurement components to measure parameters of battery components, including a signal generator to apply signals and a signal processing system to analyze reflected signals using frequency domain reflectometry and trained models to identify continuity defects and their locations within battery packs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional battery testing methods using high-voltage and high-power equipment are used, then defect detection capability is improved, but safety concerns increase and infrastructure requirements are elevated

Engineering Contradiction:

Improvedefect detection capabilityVSAvoidsafety concerns

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent changes the testing parameters from high-voltage/high-power to low-voltage alternating current (specifically 100-200 kHz AC at safe voltage levels). This parameter transformation maintains defect detection capability through frequency domain reflectometry while eliminating the safety hazards associated with high-voltage testing equipment.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces conventional high-voltage electrical testing mechanisms with an AC impedance-based measurement system. By using alternating current at specific frequencies and analyzing impedance responses, the system achieves defect detection without requiring dangerous high-voltage equipment, thus substituting a safer measurement mechanism.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If conventional battery testing equipment is used, then defect detection is achieved, but system weight and size increase

Engineering Contradiction:

Improvedefect detectionVSAvoidtesting system weight

Core Design Contradiction:

Measurement precisionVSWeight of moving object

Solution Approach 1:

By changing from high-voltage DC testing to low-voltage AC impedance testing at 100-200 kHz, the patent enables the use of lighter measurement equipment. The AC impedance measurement system requires significantly less robust power handling components, thereby reducing the overall weight of the testing system while maintaining defect detection accuracy.

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If conventional battery testing equipment is used, then defect detection is achieved, but system cost increases

Engineering Contradiction:

Improvedefect detectionVSAvoidsystem cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent transforms the testing approach to use low-voltage AC signals at 100-200 kHz frequencies, which can be generated and measured using standard, lower-cost electronic components. This parameter change eliminates the need for expensive high-voltage power supplies and specialized high-voltage measurement equipment, thereby reducing system cost while maintaining defect detection capability through impedance analysis.

Inventive Principle:

Principle #35Parameter changes

4Measurement precision

If conventional battery testing methods are used, then connector and wiring continuity is detected, but power and energy consumption increase

Engineering Contradiction:

Improvecontinuity detectionVSAvoidpower consumption

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The patent changes from high-power continuous testing to low-power AC impedance measurement at 100-200 kHz. By using small-amplitude AC signals and measuring impedance responses, the system achieves continuity detection with minimal power consumption, eliminating the high energy demands of conventional high-voltage pulse testing methods.

Inventive Principle:

Principle #35Parameter changes

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 approach reduces the weight, size, power, and cost of testing systems compared to conventional methods, while enhancing safety by using low-voltage alternating currents and optimizing defect detection through trained models.

Implementation Method 1

A signal generator such as a frequency synthesizer can generate a signal that passes through a battery system. The measurement components of the probe system can measure a signal transmitted to the battery system. For example, a probe of the measurement components can obtain reflected signals.

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

a frequency-domain reflectometry technique is used to locate the continuity defect

Methodology Applied

Scientific EffectFrequency domain reflectometry:

Data Source

PatentUS12327845B2System and method for identifying defects in an electric battery system

Publication Date: 2025.06.10 ALLOSENSE INC

AI summary

An apparatus and method for testing a battery pack are provided. Measurement components are configured to measure parameters of battery components (e.g., batteries and battery connection components) within the battery pack. Trained models are applied to signals measured by the measurement components and provide an output indicative of a condition of the battery components.