Battery Management System Common Housing Design
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Solution Overview
Problem
Current battery management systems for electric vehicles are costly due to the need for extensive insulation and separate components, leading to increased manufacturing and assembly costs, primarily because high-voltage and low-voltage components require separate housings and multiple interfaces to prevent voltage flashover.
Innovation Solution
A compact battery management system design where all high-voltage components are housed together with a common interface, reducing the need for extensive insulation and separate cables, with non-high-voltage components located outside the insulated housing, and using a thermally conductive housing for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage and low-voltage components are arranged in separate housings with extensive insulation, then protection against voltage flashover is improved, but manufacturing cost and assembly cost increase
Solution Approach 1:
The patent combines high-voltage components (battery, switching device, disconnecting device) and low-voltage components (control and monitoring device, measuring devices) into a single common housing, eliminating the need for separate housings and extensive insulation measures between high-voltage and low-voltage sections, thereby reducing manufacturing and assembly costs while maintaining safety
Solution Approach 2:
The common housing serves multiple functions: it provides mechanical protection for all components, acts as a unified structural element, and eliminates the need for separate insulation housings, thereby reducing the overall complexity and cost of the battery management system
2Reliability
If separate plugs and cable harnesses are used to connect isolated devices, then reliable isolation between high-voltage and low-voltage components is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
By placing all components in a common housing with internal connections, the patent eliminates the need for multiple external plugs and cable harnesses, simplifying the system structure while maintaining reliable electrical isolation through the housing design and interface arrangements
3Reliability
If extensive insulation measures are implemented for separate high-voltage components, then protection against voltage flashover is improved, but assembly complexity and manufacturing effort increase
Solution Approach 1:
The common housing design consolidates all insulation requirements into a single structural solution rather than requiring multiple separate insulation measures, significantly reducing assembly steps and manufacturing effort while maintaining equivalent or superior protection against voltage flashover
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 design significantly reduces insulation efforts and costs, simplifies connections, and ensures reliable protection against voltage flashover while maintaining compactness and efficiency.
Implementation Method 1
using a thermally conductive housing for efficient heat dissipation
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a battery system (10) for a battery, in particular a vehicle battery (12), comprising a measuring device (48) for at least one battery parameter, at least one switching device (40, 42, 44) for interrupting a circuit (28), a disconnecting device (46) for interrupting the circuit (28), wherein the at least one measuring device (48), the switching device (40, 42, 44) and the disconnecting device (46) are arranged in an insulated housing section (62), wherein the housing section (62) has at least one insulated interface (64, 66, 70) for contacting a control and monitoring device (58) and/or vehicle electronics (72).