Battery Module Fault Detection Using Insulated Plate Sensing
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Solution Overview
Problem
In electric aircraft, battery cell short-circuits can lead to thermal runaway, causing rapid temperature increases and potential aircraft failure, necessitating a reliable fault detection system to alert pilots of faults within battery modules.
Innovation Solution
A fault detection apparatus comprising a battery module with insulated plates and sensors to detect potential signals, allowing a controller to determine faults and prevent thermal runaway by distinguishing between local and global faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation is disposed between battery cells and plate to enable fault detection, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent introduces an insulation layer as an intermediary component between the battery cells and the plate. This insulation layer serves multiple functions: it provides electrical isolation to enable safe potential signal detection, maintains mechanical contact through compression, and creates a controlled interface for fault detection without requiring direct electrical connection between cells and plate.
Solution Approach 2:
The system utilizes the existing structural plate and insulation components to perform dual functions: mechanical support/thermal management (original functions) plus electrical isolation for fault detection (new function). The compression force already present in the battery module self-compresses the insulation layer, eliminating the need for additional compression mechanisms.
2Reliability
If sensors are added to detect potential signals for fault detection, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The plate structure serves multiple functions simultaneously: it provides mechanical support for the battery cells, acts as a thermal management interface, serves as an electrical isolation barrier through the insulation layer, and functions as a mounting substrate for sensors. This multi-functionality reduces the need for separate dedicated components for each function.
Solution Approach 2:
The insulation layer acts as an intermediary that enables sensor placement and electrical isolation without requiring sensors to be in direct contact with battery cells. This intermediate position simplifies sensor integration and reduces manufacturing complexity by avoiding direct cell-sensor interfaces.
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 effectively identifies faults in battery modules, preventing thermal runaway and ensuring pilot safety by accurately distinguishing between local and global faults, thereby reducing the risk of aircraft malfunction.
Implementation Method 1
an insulation disposed between the plurality of battery cells and the plate, wherein the insulation is configured to electrically insulate the plate from the plurality of battery cells
Implementation Method 2
a sensor configured to detect a potential signal as a function of a potential between the plate and a reference potential
Data Source
AI summary
A apparatus for fault detection for use in an electric aircraft is disclosed herein. The apparatus includes a battery module with a plurality of battery cells, a plate extending along the row of cells, insulation between the plate and the plurality of cells, a sensor configured to detect a potential signal, and a controller communicatively connected to the sensor. The controller is configured to receive the potential signal and determine a fault.