Vehicle Battery Fuse Detection via Current Profile Analysis
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Solution Overview
Problem
Existing battery systems require complex and costly monitoring devices to detect blown safety fuses, especially when multiple consumers are involved, due to the need for separate voltage measurements and additional signal processing, increasing assembly effort and system complexity.
Innovation Solution
A circuit arrangement with a current sensor and electronics unit that evaluates current profiles during pre-charging, comparing actual current or charge curves to stored target curves to determine if a safety fuse has blown, using a pre-charging circuit with a resistor to limit current and a disconnecting device to bypass sections of the load circuit, allowing for parallel load circuits with separate fuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate voltage measurements are used to detect blown fuses, then detection reliability is improved, but device complexity and installation effort increase
Solution Approach 1:
The patent combines the fuse detection function with the existing current monitoring system by evaluating current profiles during pre-charging phases. Instead of implementing separate voltage measurement circuits for each fuse, the system merges detection capabilities into the central electronics unit that already monitors current flow, thereby reducing device complexity while maintaining detection reliability
Solution Approach 2:
The electronics unit is designed to perform multiple functions: it monitors current flow for charging control, manages pre-charging phases, and detects blown fuses by evaluating current profiles. This multi-functional approach eliminates the need for dedicated voltage measurement devices, reducing overall system complexity while maintaining reliable fuse detection
2Measurement precision
If additional voltage measurement leads are installed for each fuse, then detection precision is improved, but manufacturing cost and assembly effort increase
Solution Approach 1:
The system merges fuse detection into the existing current sensing infrastructure. The same current sensor and electronics unit used for charging management are utilized to detect fuse status by analyzing current profiles, eliminating the need for additional voltage measurement leads and reducing assembly effort
Solution Approach 2:
The system uses its own current monitoring capabilities to detect fuse failures without requiring external measurement infrastructure. The electronics unit self-evaluates fuse status by comparing actual current profiles against expected profiles during pre-charging phases, eliminating the need for separate measurement leads
3Reliability
If multiple separate monitoring devices are used for each consumer circuit, then detection reliability is improved, but system complexity and cost increase
Solution Approach 1:
A single electronics unit is designed to monitor multiple consumer circuits simultaneously. The unit evaluates current profiles for each circuit during pre-charging phases and can identify which specific fuse has blown, providing comprehensive monitoring coverage without requiring separate devices for each circuit
Solution Approach 2:
The monitoring approach is segmented by evaluating current profiles for each consumer circuit independently within the unified electronics unit. The system can identify which specific circuit has a blown fuse by comparing current profiles, providing circuit-specific detection capability while using a single centralized monitoring device
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
This method allows for reliable and cost-effective detection of blown safety fuses without additional voltage measurements, simplifying maintenance and diagnosis by comparing actual current or charge profiles to expected values, distinguishing which fuse has blown and ruling out other faults.
Implementation Method 1
a pre-charge circuit connectable to the load circuit and configured to limit the current flowing through the load circuit by means of a resistor
Data Source
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AI summary
Battery system (1) comprising a plurality of cells (3), a load circuit (4) to which the voltage of the cells (3) is applied, a current sensor (5) configured to detect the current flowing in the load circuit (4), an electronic unit (6) configured to evaluate signals from the current sensor (5), a pre-charge circuit (7) connectable to the load circuit (4) configured to limit the current flowing through the load circuit (4) by means of a resistor (7.1), a disconnecting device (8) in a section of the load circuit (4), wherein this section can be bridged by the pre-charge circuit (7), a first consumer circuit (9.1) and at least a second consumer circuit (9.2) arranged in parallel to each other and connected to the load circuit (4), wherein each consumer circuit (9.1, 9.2, 9.3) has at least one fuse (10.1, 10.2, 10.3).3) is assigned, wherein the electronic unit (6) is configured to infer, based on signals from the current sensor (5), whether one of the fuses (10.1, 10.2, 10.3) has blown, as well as a vehicle (2) with the battery system (1) and a method for operating the battery system (1) in a vehicle (2).