Battery Module Controller Integration on Cover
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Solution Overview
Problem
Existing battery modules require bulky wire harnesses for monitoring, occupying valuable space and causing delays in assembly and less accurate readings due to remote controllers.
Innovation Solution
A battery module design with buss bars connecting adjacent cells and a module controller integrated into a battery cover, eliminating the need for individual wires and allowing direct voltage monitoring, using ring terminals and voltage signal pins for electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wire harnesses are used to connect the central controller to each cell terminal, then voltage monitoring is achieved, but valuable space is occupied and assembly time increases
Solution Approach 1:
The patent combines the central controller with the battery module structure by integrating it into the battery cover, eliminating the need for separate wire harnesses to connect remote controllers to each cell terminal. This merging of functions resolves the contradiction by achieving both space savings and assembly time reduction while maintaining monitoring capability through direct electrical connections via buss bars
2Measurement precision
If a remote central controller is used to monitor battery cells, then voltage monitoring is achieved, but space is occupied and response delay occurs
Solution Approach 1:
The controller is merged with the battery module by integrating it directly into the battery cover structure, eliminating the need for a separate remote controller location. This integration removes the dedicated space requirement while maintaining full voltage monitoring capability through electrical connections to the buss bars
Solution Approach 2:
The buss bars serve as intermediaries that provide direct electrical connection between the integrated controller and all battery cells. This intermediary structure enables the controller to monitor all cells without requiring individual wire harnesses, thus reducing space occupancy while maintaining monitoring precision
3Measurement precision
If individual wires are used to connect each cell to the controller, then voltage monitoring is achieved, but assembly complexity and time increase
Solution Approach 1:
The patent merges multiple individual wire connections into a single buss bar structure that provides electrical connection to all battery cells. This consolidation reduces assembly complexity by eliminating the need to attach individual wires to each cell while maintaining the capability to monitor individual cell voltages through the integrated controller
Solution Approach 2:
The buss bars serve multiple functions simultaneously: they provide electrical connection for current flow between cells and serve as signal pathways for voltage monitoring. This multi-functionality reduces overall system complexity by eliminating the need for separate monitoring wires while maintaining individual cell monitoring capability
Data Source
AI summary
A battery module includes battery cells arranged side-by-side in a stacked configuration, the battery cells having positive and negative cell terminals. Buss bars are electrically connected to corresponding cell terminals to electrically connect adjacent battery cells. A battery cover coupled to the battery cells. A module controller is held by the battery cover and is electrically connected to the buss bars to monitor a voltage of the corresponding buss bar.