Modular Battery Module PCB Layout for Faster Board Replacement
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Solution Overview
Problem
The existing battery module and pack assembly processes are inefficient in terms of manufacturing and maintenance, particularly due to the complexity and rigidity of printed circuit board arrangements, which hinders easy replacement and monitoring of battery cells.
Innovation Solution
A modular design incorporating separable printed circuit boards that can be attached and detached in multiple directions, with a cell monitoring system that includes a first board for data collection and a second board for data transmission to a controller, utilizing connectors for easy coupling and decoupling, and a wireless communication system for remote monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If printed circuit boards are fixed rigidly in battery module, then structural stability is improved, but manufacturing efficiency and maintenance efficiency deteriorate
Solution Approach 1:
The printed circuit board system is divided into multiple separable boards (first board for data collection, second board for data transmission) that can be independently attached and detached. This segmentation allows efficient manufacturing and maintenance operations while maintaining structural stability through modular assembly.
Solution Approach 2:
The printed circuit boards are designed with dynamic attachable/detachable connections rather than fixed rigid mounting. This enables the system to transition between stable operational state and easily separable state for manufacturing or maintenance, resolving the contradiction between structural stability and manufacturing efficiency.
2Stability of the object's composition
If printed circuit boards are fixed rigidly in battery module, then structural stability is improved, but maintenance efficiency deteriorates
Solution Approach 1:
The monitoring system uses segmented printed circuit boards that can be independently accessed and replaced. The first board and second board are separable, allowing maintenance personnel to replace only the faulty board without disassembling the entire module, thus improving maintenance efficiency while maintaining structural integrity.
Solution Approach 2:
The printed circuit boards are designed to be extractable from the battery module through detachable connections. This extraction capability enables easy removal and replacement of boards for maintenance purposes without compromising the overall structural stability of the battery module.
3Ease of repair
If entire battery module is disassembled for board replacement, then board replacement is possible, but downtime increases
Solution Approach 1:
The system is segmented into independently replaceable printed circuit boards within the battery module. This allows replacement of only the specific board that requires maintenance rather than disassembling the entire module, significantly reducing downtime while maintaining full replacement capability.
Solution Approach 2:
The detachable connection system is pre-configured to enable quick board replacement without extensive disassembly. This preliminary design of separable connections allows maintenance personnel to perform rapid board swaps, minimizing downtime while ensuring complete replacement capability when needed.
Data Source
AI summary
A battery module and a battery pack including the same are disclosed.In some implementations, the battery module may include a plurality of battery cells; and a cell monitoring portion connected to the plurality of battery cells, the cell monitoring portion including a plurality of boards collecting information on at least one of temperature, current, and voltage of the plurality of battery cells. The plurality of boards may be separable.