Battery Module Overheat Detection Using Parallel Thermal Fuse Coding
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Solution Overview
Problem
Current battery management systems (BMS) in electric vehicles cannot specifically determine which battery module is overheated, leading to potential safety risks, as they rely on general temperature sensors that cannot accurately identify overheated modules, and adding sensors for each module is impractical due to increased complexity and cost.
Innovation Solution
The use of thermal fuses with different resistance values connected in parallel, where a controller measures the total resistance value to detect overheating by referencing a stored table of resistance values, and a third fuse helps differentiate between overheating and connector issues, allowing for precise identification of overheated modules and triggering warnings or power cutoffs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is provided for each battery module, then the precision of overheating detection is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The battery pack is segmented into multiple battery modules, and each module is assigned a unique thermal fuse with a distinct resistance value. This segmentation allows the system to identify which specific module is overheating by measuring the total resistance of the parallel-connected thermal fuses, eliminating the need for multiple temperature sensors while maintaining module-level detection precision.
Solution Approach 2:
The invention changes the parameter used for temperature detection from temperature directly (using temperature sensors) to resistance value (using thermal fuses with different resistance values). By measuring the equivalent resistance of parallel-connected thermal fuses and comparing it against pre-stored reference values, the system can identify overheated modules without requiring complex sensor installations.
2Reliability
If multiple temperature sensors are installed to detect each battery module, then the reliability of safety monitoring is improved, but the manufacturing cost increases
Solution Approach 1:
The thermal fuses serve multiple functions: they act as both temperature-sensitive elements and resistance indicators. Each thermal fuse is designed with a specific resistance value that corresponds to its associated battery module, allowing a single component to perform both protection and identification functions, thereby reducing the need for additional sensors and lowering manufacturing costs.
Solution Approach 2:
Instead of using expensive temperature sensors for each module, the invention uses thermal fuses with different resistance values as a simplified copy or alternative approach. The resistance values serve as unique identifiers for each module, enabling the system to detect overheating conditions reliably without requiring multiple identical sensor components.
3Measurement precision
If thermal fuses with different resistance values are used connected in parallel, then the precision of identifying overheated modules is improved, but the device complexity increases
Solution Approach 1:
The controller continuously monitors the equivalent resistance of the parallel-connected thermal fuses and compares it against pre-stored reference resistance values for each battery module configuration. This feedback mechanism enables the system to automatically identify which module is overheating based on resistance changes, maintaining high identification precision while using a relatively simple parallel circuit configuration.
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 enables accurate detection of overheated battery modules, preventing potential fires by providing precise identification and enabling timely warnings or power cutoffs, thus enhancing safety and reducing the complexity of sensor installation.
Implementation Method 1
a plurality of thermal fuses having different resistance values and is capable of detecting an overheated battery module based on a resistance value due to disconnection of at least one temperature fuse
Implementation Method 2
a controller that detects an overheated battery module based on a total resistance value of the first and second temperature fuses, which are connected in parallel to each other
Data Source
AI summary
An apparatus for detecting overheating of a battery module includes a battery pack including a first battery module and a second battery module, a first temperature fuse arranged on the first battery module and having a first resistance value, a second temperature fuse arranged on the second battery module and having a second resistance value, and a controller that detects an overheated battery module based on a total resistance value of the first and second temperature fuses, which are connected in parallel to each other.