Battery Pack Isolation Resistance Measurement Without Full Charge
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Solution Overview
Problem
Existing methods for determining isolation resistance in battery packs are time-consuming and costly, requiring batteries to be fully charged and are influenced by charging degree, which can lead to inaccurate measurements and increased corrosion risk.
Innovation Solution
A system and method that iteratively applies predetermined voltage levels between electrical terminals of a battery pack, using a voltage meter and microprocessor to measure voltage levels and calculate isolation resistance values without the need for the battery to be fully charged, allowing for accurate determination of isolation resistance without series coupling of battery modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the battery is fully charged to measure isolation resistance, then the measurement can be performed, but the time and cost increase tremendously
Solution Approach 1:
The patent applies preliminary action by performing isolation resistance measurement at an early stage during battery assembly or testing, before the battery is fully charged. The measurement is conducted on the battery pack at a state where it is not fully charged, thereby avoiding the time-consuming full charging process while still obtaining valid isolation resistance data for quality control purposes.
2Measurement precision
If the battery is fully charged to measure isolation resistance, then the measurement can be performed, but the cost increases tremendously
Solution Approach 1:
The patent performs isolation resistance measurement at an early stage before full charging is completed, thereby avoiding the waste of energy that would be consumed during complete charging cycles solely for measurement purposes. This preliminary measurement approach significantly reduces energy loss while maintaining measurement effectiveness.
3Loss of time
If the isolation resistance is not measured accurately, then time and cost are saved, but the corrosion risk increases
Solution Approach 1:
The patent performs isolation resistance measurement at an early stage in the battery lifecycle, before corrosion can significantly degrade the metal layer. By measuring isolation resistance preliminarily when the battery is not fully charged, the system captures accurate data before degradation occurs, ensuring reliability without requiring time-consuming full charging cycles.
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 accurate and efficient determination of isolation resistance without the need for full battery charge, reducing time and cost while minimizing corrosion risks by iteratively measuring voltage levels and calculating resistance values.
Implementation Method 1
determining isolation resistance values by iteratively determining a plurality of voltage levels between a first electrical terminal and a second electrical terminal of the battery pack
Implementation Method 2
measuring a first voltage level between the first electrical terminal and the housing when the first output voltage level is being output
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A system for determining isolation resistances of a battery pack includes a voltage source, a voltage meter, and a microprocessor. The voltage source is disposed external of the battery pack. The voltage source applies an output voltage on first and second electrical terminals. The voltage meter measures a first voltage level between the first electrical terminal and the housing, and a second voltage level between the first electrical terminal and the housing when a resistor is electrically coupled between the first electrical terminal and the housing. The voltage meter measures a third voltage level between the second electrical terminal and the housing, and a fourth voltage level between the second electrical terminal and the housing when the resistor is electrically coupled between the second electrical terminal and the housing. The microprocessor determines a first isolation resistance value based on the first, second, and third voltage levels.