Battery Module Location Mapping Using Wiring and Sensor Signals

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Solution Overview

Problem

The installation of battery energy storage systems is difficult and time-consuming, and manual inventorying of energy storage module locations is prone to errors, necessitating a more efficient and accurate method for mapping module locations.

Innovation Solution

A modular battery energy storage system with a controller and monitoring circuits that utilize a wiring network, resistor networks, or magnetic sensors to automatically map module locations, enabling precise identification and communication of each module's position within the frame.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual inventorying of energy storage module locations is performed by scanning bar codes or noting serial numbers, then module location identification can be achieved, but the process is time-consuming and prone to errors

Engineering Contradiction:

Improvemodule location identification accuracyVSAvoidinstallation and inventorying time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical inventorying processes (scanning bar codes, noting serial numbers) with an automated electrical sensing system. The system uses sensing circuits that automatically detect and map module locations through electrical connections during installation, eliminating the need for manual recording and reducing both time and error rates.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service mapping where the battery energy storage system automatically generates its own location map during installation. The sensing circuits autonomously detect module positions and the controller automatically creates the location mapping without requiring installer intervention for inventorying, thus reducing installation time and improving accuracy.

Inventive Principle:

Principle #25Self-service

2Ease of operation

If manual inventorying procedures are used to identify each module location, then location mapping can be generated, but the process is difficult and time-consuming

Engineering Contradiction:

Improveease of module location mappingVSAvoidinstallation speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces complex manual inventorying procedures with an automated electrical sensing system that seamlessly integrates into the installation process. The sensing circuits and controller automatically map module locations as modules are connected, making the process easier to perform and significantly increasing installation productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs location mapping as a preliminary action during the installation process itself, rather than as a separate post-installation step. By integrating the sensing circuits that detect module locations during connection, the system automates the mapping process and eliminates the need for separate manual inventorying, thereby improving both ease of operation and productivity.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If manual identification of module locations is performed, then location data can be recorded, but errors are prone to occur

Engineering Contradiction:

Improveaccuracy of module location dataVSAvoidcomplexity of mapping system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces error-prone manual identification processes with an automated electrical sensing system. The sensing circuits objectively detect module locations through electrical connections and the controller automatically processes this data, eliminating human errors while maintaining acceptable system complexity through integration with existing battery management infrastructure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs self-service location mapping where the battery energy storage system automatically generates and stores accurate location data during installation. The sensing circuits and controller work autonomously to create the location map, ensuring data accuracy while keeping the added complexity minimal by utilizing the system's existing electrical architecture.

Inventive Principle:

Principle #25Self-service

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

Facilitates quick and accurate mapping of energy storage module locations, simplifying return merchandise authorization and repair processing by eliminating manual errors and reducing installation time.

Implementation Method 1

magnetic sensors to automatically map module locations

Methodology Applied

Scientific EffectMagnetic field sensing: Magnetic Field

Data Source

PatentUS20260016544A1Method and apparatus for mapping energy storage module location in a modular battery energy storage system

Publication Date: 2026.01.15 ENPHASE ENERGY INC

AI summary

A method and apparatus for mapping energy storage module locations in a modular battery energy storage system. The apparatus comprises a plurality of energy storage modules, arranged in an array within a frame, for storing energy and electrically connected to at least one wiring harness to interconnect the plurality of energy storage modules. The plurality of energy storage modules are coupled to an energy storage module mapping system for determining a physical location of each energy storage module within the array of energy storage modules based upon signals from the energy storage modules.