Battery Discharge System with Segmented Cell Control
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Solution Overview
Problem
Existing battery discharge systems for decommissioned electric vehicle packs are ineffective in safely and automatically draining energy, especially in damaged or accident-damaged packs, due to potential short circuits, charge imbalances, and impaired thermal management, posing safety risks to passengers and rescue workers.
Innovation Solution
A battery discharge system comprising a low-power controller and switched discharge elements, activated by external sensors or a panic button, which verifies safe temperature conditions before initiating a forced discharge of battery cells through a discharge load, ensuring controlled energy depletion even in damaged packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If an external resistor bank is connected to the battery terminal to drain stored energy, then energy can be depleted, but the solution fails when the battery electrical circuit is damaged with open circuits between cells
Solution Approach 1:
The battery pack is divided into multiple modules, each with its own discharge circuit. Switches are connected in parallel across individual battery cells or small groups of cells, allowing discharge to proceed through alternative paths when other cells are damaged or have open circuits. This segmentation ensures that damage to one portion of the battery does not prevent discharge of the entire pack.
2Loss of energy
If an external resistor bank is connected to drain energy, then energy depletion is possible, but cell resistance increases quickly when a cell is near empty due to charge imbalance, preventing other cells from being depleted
Solution Approach 1:
A controller continuously monitors the voltage and state of charge of individual battery cells through voltage dividers and ADC circuits. Based on this feedback, the controller dynamically adjusts which switches are closed to direct discharge current from cells that still have charge, preventing the charge imbalance problem where one cell depletes too quickly and increases resistance.
3Loss of energy
If manual discharge procedures are used with external loads, then energy can be drained, but the process is not automatic and cannot respond quickly to accidents
Solution Approach 1:
The discharge switches and circuitry are pre-installed within the battery pack housing, ready for immediate activation. Crash sensors and other triggering mechanisms are pre-positioned to detect accidents automatically. When an accident occurs, the system activates the discharge process automatically without requiring manual intervention, responding quickly to drain energy and prevent fires or shocks.
4Use of energy by moving object
If the battery pack is designed with high energy content for vehicle operation, then vehicle performance is improved, but safety risks increase during decommissioning due to potential fires and shock hazards
Solution Approach 1:
The battery pack incorporates an integrated discharge system with switches, resistors, and control circuitry built into the housing during manufacturing. This preliminary preparation ensures that when the vehicle is decommissioned or involved in an accident, the high energy content can be safely and quickly dissipated through pre-positioned discharge paths, cushioning against the harmful effects of fires, shocks, or thermal runaway.
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 system safely and automatically drains energy from decommissioned battery packs, minimizing safety risks by ensuring controlled discharge, even in damaged or accident-damaged conditions, thereby preventing fires and electrical hazards.
Implementation Method 1
at least one discharge load connected in series with the battery cells
Data Source
AI summary
A battery based power supply assembly is disclosed. The system comprises a discharge initiating device and a plurality of battery modules electrically connected with one another. Each of the battery modules comprises a plurality of battery cells, a discharge load connected in series with the battery cells, a switch coupled between the battery cells and the discharge load, a temperature sensor, and a controller adapted for placing the switch in its electrically connected state upon being driven by the discharge initiating device. The invention further provides a safe method of draining the energy from the power supply assembly disclosed herein.