Battery Enclosure Impact Classification for Vehicle Underside Strikes
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Solution Overview
Problem
Existing vehicles, particularly battery electric vehicles, face challenges in detecting and classifying impacts on the underside that could potentially damage the battery enclosure, leading to safety hazards such as thermal runaway or coolant leakage, which may not be immediately apparent and require timely evacuation or maintenance.
Innovation Solution
A system utilizing impact sensors, including strain gauges and accelerometers, combined with battery condition sensors, processes sensor outputs to classify the severity of impacts on the battery enclosure by comparing with impact characterizing data derived from simulations and real-world data, enabling the vehicle to take appropriate actions based on the classification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If impact sensors and battery condition sensors are installed on the battery enclosure, then the ability to detect and classify impact severity is improved, but the device complexity and cost increase
Solution Approach 1:
The battery enclosure is divided into multiple zones with different sensor densities. High-risk areas (such as areas above battery cells and coolant channels) have higher sensor density, while low-risk areas have lower density. This segmented approach provides adequate detection coverage for critical areas without unnecessarily increasing overall system complexity and cost.
Solution Approach 2:
Different sensor types and densities are applied to different locations on the battery enclosure based on local risk assessment. Strain gauges, accelerometers, and contact sensors are strategically placed in areas most vulnerable to impact damage, while areas with lower risk receive fewer or different types of sensors.
2Reliability
If a protective plate is added to the battery enclosure underside, then the battery protection against impact is improved, but the weight and device complexity increase
Solution Approach 1:
A protective plate is installed on the underside of the battery enclosure to absorb and distribute impact forces before they reach the battery cells. This pre-positioned protective element cushions against debris and impacts, reducing the need for heavier overall battery housing structures.
Solution Approach 2:
The protective plate and battery enclosure are designed using composite material structures that provide high strength-to-weight ratios. This allows adequate protection against impact while minimizing the additional weight compared to solid metal constructions.
3Measurement precision
If multiple sensor types (strain gauges, accelerometers, contact sensors) are used, then the impact classification accuracy is improved, but the device complexity and data processing requirements increase
Solution Approach 1:
Multiple sensor types (strain gauges, accelerometers, contact sensors) are combined in a unified sensor arrangement on the battery enclosure. These sensors work together to provide complementary data about impact events, enabling more accurate classification of impact severity through data fusion rather than requiring separate independent systems.
Solution Approach 2:
The sensor arrangement is designed to serve multiple functions: detecting impact presence, classifying impact severity, determining impact location, and monitoring battery condition. This multi-functional approach reduces the need for separate specialized systems for each function.
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
Enables vehicles to accurately assess the severity of impacts on the battery enclosure, allowing for timely and appropriate responses such as evacuation or continued operation to a safe location, thereby enhancing safety and reducing the risk of battery failure.
Implementation Method 1
The impact sensor arrangement comprises strain gauges associated with the protective panel
Implementation Method 2
The impact sensor arrangement comprises accelerometers associated with the underside of the battery enclosure
Implementation Method 3
The one or more processors may be configured to compare a distribution of magnitudes of impact sensor outputs as a function of position on the protective panel with impact characterizing data
Data Source
AI summary
An impact with a battery enclosure of a vehicle is classified based at least on processing impact sensor outputs to generate battery impact classification data. The impact sensor outputs are received from an impact sensor arrangement associated with the battery enclosure, the impact sensor arrangement being configured to generate the impact sensor outputs in response to a deformation of the battery enclosure. The vehicle is caused to perform an action in response to the battery impact classification data.