Battery Pack Fuse Failure Detection for Current-Limited Vehicle Operation

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Solution Overview

Problem

Existing battery packs in vehicles lack the ability to accurately determine the number of blown fuses, which hinders the adjustment of electrical loads to accommodate new power limits, leading to potential overloading of remaining cells.

Innovation Solution

A system and method that utilizes sensors and a processor to calculate an expected value of battery parameters, compare measured values to determine blown fuse conditions, and adjust the vehicle's operational state based on available current.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the battery pack continues to operate without detecting blown fuses, then the vehicle can maintain operation, but the remaining functional cells may become overloaded and fail

Engineering Contradiction:

Improvebattery pack operation continuityVSAvoidoverloading of remaining cells

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system continuously monitors battery parameters (voltage, current, temperature) and compares measured values against expected values from the battery model. When deviations indicate blown fuses, the system provides feedback to adjust electrical loads and available current limits, preventing overloading of remaining cells while maintaining operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system proactively detects blown fuses by comparing measured battery parameters against model expectations before overloading occurs. By identifying fuse failures early through parameter comparison, the system can pre-adjust electrical loads and current limits to prevent harmful overloading of remaining functional cells.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the system adjusts electrical loads based on detected fuse failures, then the battery pack operates safely, but the vehicle's power availability is reduced

Engineering Contradiction:

Improvesafe operationVSAvoidavailable electrical power

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

The system dynamically adjusts the available current and electrical load limits based on the detected number of blown fuses. Rather than static power reduction, the system optimizes power availability in real-time by comparing measured parameters against model expectations, allowing maximum safe power delivery while preventing overloading.

Inventive Principle:

Principle #15Dynamics

3Device complexity

If the battery pack lacks fuse detection capability, then the system remains simple, but the number of blown fuses cannot be determined for load adjustment

Engineering Contradiction:

Improvesystem simplicityVSAvoidnumber of blown fuses

Core Design Contradiction:

Device complexityVSLoss of information

Solution Approach 1:

The system replaces complex mechanical fuse detection mechanisms with an electronic diagnostic approach. By using sensors to measure battery parameters (voltage, current, temperature) and comparing these against a computational battery model, the system infers the number of blown fuses without requiring direct mechanical detection, maintaining relative simplicity while gaining diagnostic capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12385982B2Diagnostics and mitigation of battery cell failure with passive disconnect

Publication Date: 2025.08.12 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A vehicle includes a system that performs method operating a battery pack of the vehicle. The system includes one or more sensors and a processor. The one or more sensors obtain a measured value of a battery parameter of the battery pack. The processor is configured to calculate an expected value of the battery parameter from a model of the battery pack, compare the measured value to the expected value to determine a blown fuse condition of the battery pack, determine an available current from the battery pack based on the blown fuse condition, and control an operational state of the vehicle based on the available current.