Battery Module Interface Testing for Safe High-Voltage Diagnostics
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Solution Overview
Problem
Existing battery testing methods for multi-module systems, particularly in high voltage installations, face challenges in safely and effectively determining the status of individual battery modules and the overall system, often requiring disassembly or direct human intervention, and fail to predict module degradation before failure.
Innovation Solution
A battery management system with a controller device and module interface devices that allow independent connection, disconnection, and measurement of battery modules at controlled voltage and power levels, enabling safe and predictive testing without physical disconnection, using measurement and switching circuits to obtain module-specific and load-specific operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery testing methods are used for multi-module systems, then testing can be performed, but safety risks increase and human intervention is required
Solution Approach 1:
The battery management system performs self-testing of individual battery modules through automated switching circuits and measurement circuits, eliminating the need for human disassembly or direct intervention. The system independently connects, disconnects, and measures each module's operating conditions without external assistance.
Solution Approach 2:
The patent introduces a battery management system with switching circuits and measurement circuits as intermediaries between the battery modules and the testing process. These intermediary components enable safe, automated measurement of module-specific and load-specific operating conditions without requiring direct human contact with high-voltage battery components.
2Measurement precision
If individual battery modules are tested in multi-module systems, then module status can be determined, but system complexity increases
Solution Approach 1:
The battery system is segmented into individual testable modules, with the battery management system capable of isolating and testing each module independently through switching circuits. This segmentation allows precise measurement of each module's status while maintaining overall system organization through systematic control procedures.
Solution Approach 2:
The battery management system performs multiple functions through integrated switching and measurement circuits that can handle both module-specific testing and load-specific measurements. The same system infrastructure supports various testing scenarios (individual module testing, group testing, full system testing) without requiring separate dedicated equipment for each function.
3Measurement precision
If battery modules are tested while connected to electrical load, then operational status can be measured, but safety risks increase due to high voltage
Solution Approach 1:
Measurement circuits are introduced as intermediary components that safely interface with battery modules during operational testing. These intermediary measurement circuits enable the acquisition of module-specific and load-specific operating conditions (voltage, current, temperature) while maintaining electrical isolation and safety protocols, allowing accurate measurements without direct exposure to high-voltage dangers.
Solution Approach 2:
The battery management system performs self-measurement of operating conditions through integrated measurement circuits that monitor module voltage, current, and other parameters during normal operation. The system independently collects and processes this data without requiring external testing equipment or human intervention, maintaining both measurement accuracy and safety.
Data Source
AI summary
A method, a battery management system, and an article of manufacture for testing a battery system are disclosed. The battery system can include a plurality of battery modules. A test process is performed with respect to the battery system via the battery management system that includes a controller device and a plurality of module interface devices. For each battery module of the plurality of battery modules, a respective module interface device of the plurality of module interface devices is operatively coupled to anode and cathode terminals of that battery module. Each module interface device can include a measurement circuit and a switching circuit. The test process can be used to independently connect, disconnect, and measure various operating conditions of the battery modules and load.