Capacitive Battery Housing Deformation Detection in Tight Vehicle Space

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Solution Overview

Problem

Existing deformation detection systems for energy storage assemblies in vehicles struggle to effectively detect both significant and minor mechanical deformations within restricted installation spaces while ensuring robustness against mechanical stresses, often relying on sacrificial components for energy dissipation.

Innovation Solution

A deformation detection device integrated into the vehicle support structure, featuring an outer and inner electrically conductive sensing element forming a capacitor with an electrically insulating component and damping material, allowing for the detection of changes in electrical parameters such as capacitance and voltage, enabling the differentiation of deformation levels and providing a warning mechanism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the installation space in the vehicle vertical direction is highly restricted and energy storage cells are arranged densely, then the quantity of energy storage cells increases, but the robustness of the high-voltage store with respect to mechanical stresses decreases

Engineering Contradiction:

Improvequantity of energy storage cellsVSAvoidrobustness with respect to mechanical stresses

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The high-voltage store is divided into multiple energy storage cells arranged in a segmented configuration. Each cell is independently protected by its own sensor element, allowing the system to maintain structural integrity through modular segmentation while maximizing cell quantity within restricted vertical space.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Sensor elements are integrated into the housing structure beforehand to detect mechanical deformations before they lead to catastrophic failure. This prior detection capability allows for preventive measures to be taken, cushioning against the worst-case scenarios of mechanical stress while maintaining dense cell arrangement.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If peripheral and/or sacrificial components are used to dissipate energy in mechanical over-stressing, then the supporting structural components are protected, but the complexity of the mechanical damage chain increases

Engineering Contradiction:

Improveprotection of supporting structural componentsVSAvoidcomplexity of mechanical damage chain

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical damage chains with an electrical sensing system. Instead of relying on peripheral components to dissipate mechanical energy through controlled failure, the system uses sensor elements that detect deformations electrically, substituting mechanical protection mechanisms with an electrical monitoring and warning system that simplifies the overall structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Sensor elements act as intermediaries between the housing structure and the control system. These sensors detect mechanical deformations and transmit electrical signals to trigger warning messages, serving as a mediating layer that protects the energy storage system without requiring complex mechanical damage chains or sacrificial components.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If only serious defects are detected by existing deformation detection systems, then the device complexity is reduced, but the measurement precision of deformation detection decreases

Engineering Contradiction:

Improvesimplicity of detection systemVSAvoiddetection capability of deformation levels

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The sensor elements are designed to detect a wide range of deformation parameters, from slight to major deformations, by monitoring electrical parameter changes in the housing structure. This parameter-based detection approach enables the system to maintain simplicity while achieving high measurement precision across multiple deformation levels, triggering appropriate warning messages based on the severity detected.

Inventive Principle:

Principle #35Parameter changes

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 solution allows for the detection of both minor and major deformations, enabling a nuanced response to damage levels and minimizing potential damage by providing timely warnings, while optimizing space usage and ensuring robustness against mechanical stresses.

Implementation Method 1

an evaluation unit which is set up to detect a change, in particular a reduction, of an electrical operating parameter, in particular a capacitance and/or a charge, of a capacitor formed by the inner sensing element and the outer sensing element

Methodology Applied

Scientific EffectCapacitance: Capacitance

Data Source

PatentUS20240167802A1Compact Deformation Detection Device for an Energy Store

Publication Date: 2024.05.23 BAYERISCHE MOTOREN WERKE AG

AI summary

A deformation detection device and method for an energy storage assembly integrated in a vehicle support structure of a motor vehicle having an energy store and a housing structure, includes an outer sensing element which is formed as or on an outer housing structure element, an inner sensing element which is formed as or on an inner energy storage element, and an evaluation unit which is designed to detect a change in an electrical operating parameter.