Battery Module Harness Clip Layout for Secure Temperature Sensing
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Solution Overview
Problem
Existing battery module technologies face challenges in accurately and reliably monitoring temperature across vehicle traction batteries due to insecure sensor placement and fragile electrical connections, which can be dislodged by vibrations and shocks, affecting the reliability of temperature readings and overall battery health monitoring.
Innovation Solution
A harness assembly for battery modules featuring an electrically conductive track along the side of the battery module, secured by harness clips that hold temperature sensors in contact with electrical cells, ensuring secure and robust connections, including thermally conductive potting for improved thermal contact, and a branch track for monitoring different regions and potential gas venting events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are placed in battery modules for monitoring, then temperature monitoring capability is improved, but the sensors can be dislodged by vibrations and shocks reducing reliability
Solution Approach 1:
The temperature sensor is integrated with the electrical connection track into a single harness assembly. The sensor is mounted on the track which is then fastened to the battery module as one unit, ensuring that the sensor remains securely positioned relative to the cells throughout the module's operational life, eliminating the dislodgement issue while maintaining monitoring accuracy.
Solution Approach 2:
The temperature sensor is pre-positioned and secured to the electrical track during harness assembly manufacturing, before the harness is installed in the battery module. This preliminary securing ensures the sensor cannot be dislodged during module assembly or subsequent vehicle operation, while the track's electrical connections provide additional mechanical anchoring.
2Reliability
If electrical connections are made securely to withstand vibrations and shocks, then connection reliability is improved, but the assembly complexity increases
Solution Approach 1:
The electrical connection track and temperature sensor mounting functions are merged into a single integrated harness assembly. By fastening the track to the battery module structure at multiple points, both the electrical connections and the temperature sensor are simultaneously secured against vibrations and shocks, achieving reliable connections without requiring separate complex mounting mechanisms for each component.
3Measurement precision
If multiple temperature sensors are installed to monitor different regions, then monitoring coverage is improved, but the risk of gas venting damage to track increases
Solution Approach 1:
The temperature sensor is extracted from direct contact with the electrical track, being mounted on top of the track rather than in close proximity to the electrical connections. This spatial separation allows multiple sensors to be installed along the track length for comprehensive monitoring coverage, while the track itself remains positioned to minimize exposure to gas venting events, reducing the risk of electrical damage.
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 solution provides a secure, reliable, and compact temperature monitoring system that maintains accurate readings over the battery's lifetime, enhancing battery health monitoring and safety by preventing damage from vibrations and allowing for quick detection of potential gas venting events.
Implementation Method 1
The thermistor may be potted in thermally conductive material
Data Source
AI summary
Disclosed is a harness assembly for a battery module of an electric vehicle, the battery module comprising first and second opposite end faces with a side located therebetween. The harness assembly comprises an electrically conductive track configured to be located along the side of the battery module; a temperature sensor electrically connected to the track; and a harness clip configured to fasten the track to the battery module and hold the temperature sensor in contact with an electrical cell of the battery module. Also disclosed is a harness comprising a primary track comprising a printed electrical conductor and configured to be located along the side of the battery module; and a branch track comprising a printed electrical conductor, electrically connected to the electrical conductor of the primary track and configured to be folded to locate it at least partially at a second side, different to the first side, of the battery module.