Battery Insulation Voltage Sensing During Charging

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Solution Overview

Problem

Existing battery testing apparatuses require temporary suspension of charging operations to test insulation voltage, leading to inefficiencies in time and effort.

Innovation Solution

An apparatus and method that allow simultaneous charging and insulation voltage sensing in battery devices by using a power switch to control charging current and an insulation voltage sensing circuit connected to the chassis ground, enabling voltage sensing during both charging and insulation testing without interrupting the charging process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If charging operation is suspended to test insulation voltage, then insulation voltage can be tested accurately, but testing time increases and productivity decreases

Engineering Contradiction:

Improveinsulation voltage measurementVSAvoidtesting efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent enables continuous charging operation while simultaneously performing insulation voltage sensing. The power switch controls charging current flow, and the insulation voltage sensing circuit measures insulation voltage during the charging process without requiring suspension of the charging operation, thus maintaining continuous useful action and improving productivity while ensuring measurement accuracy.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The battery testing apparatus is designed to perform multiple functions simultaneously: charging the battery through the power switch and sensing circuit, and measuring insulation voltage through the insulation voltage sensing circuit connected to chassis ground. This multi-functionality allows the same apparatus to handle both charging and insulation testing without requiring separate equipment or interrupting operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If separate insulation testing apparatus is used, then insulation voltage can be tested, but device complexity increases

Engineering Contradiction:

Improveinsulation voltage measurementVSAvoidtesting apparatus structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent combines the insulation voltage sensing circuit with the existing battery charging apparatus. The insulation voltage sensing circuit is integrated into the same system, sharing common components such as the microcontroller and power switch, rather than using a separate standalone insulation testing device. This merging reduces overall device complexity while maintaining measurement capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Measurement precision

If high voltage is applied for insulation testing, then insulation state can be detected, but risk of component damage increases

Engineering Contradiction:

Improveinsulation state detectionVSAvoidcomponent damage risk

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent employs a voltage divider circuit using resistors to step down the insulation voltage to a safe level for measurement. Instead of applying high voltage directly to the measurement circuit, the system uses a protective resistor network that limits voltage and current, sacrificing minimal power dissipation in the resistors to protect the sensitive measurement components from damage.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The insulation voltage sensing circuit includes protective resistors connected in series with the measurement terminals, which beforehand cushion or limit the voltage and current that can reach the sensitive measurement components. This pre-protective measure prevents potential damage from high voltage spikes or insulation failures before they can harm the measurement circuit.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

Enables efficient testing of insulation voltage without stopping the charging process, reducing testing time and effort, and eliminates the risk of component damage from high voltage applications.

Implementation Method 1

an insulation voltage sensing circuit connected to a chassis ground of the battery device, connected to a plus terminal or a minus terminal of a power terminal of the battery device when the power switch is in a turned-off state, and configured to sense an insulation voltage of the battery device

Methodology Applied

Scientific EffectVoltage sensing: Electric Field

Data Source

PatentUS20240402257A1Apparatus and method for testing battery

Publication Date: 2024.12.05 SK ON CO LTD

AI summary

An apparatus for testing a battery includes a power unit configured to generate a charging current; a power switch connected between the power unit and a power terminal of a battery device and configured to be repeatedly in a turned-on state and a turned-off state; an insulation voltage sensing circuit connected to a chassis ground of the battery device, connected to a plus terminal or a minus terminal of a power terminal of the battery device when the power switch is in a turned-off state, and configured to sense an insulation voltage of the battery device; and a selection switch configured to connect one of a plus (+) terminal or a minus (−) terminal of the power terminal of the battery device to the insulation voltage sensing circuit when the power switch is in the turned-off state.