Battery Module Pressing Test for Fast Swelling Pressure Simulation
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Solution Overview
Problem
Conventional pressure testing of battery modules is time-consuming and difficult to control, as it simulates the swelling of battery cells by repeated charging and discharging, which takes a long time and lacks precise control over the pressure applied to the module case.
Innovation Solution
A device and method that include a pressure plate and pressure driver to simulate the expansion and contraction of battery cells by pressurizing and depressurizing them in the same direction as the swelling, using a hydraulic pump and pressure members to apply controlled pressure, along with sensors to measure pressure and displacement, allowing for efficient simulation of the pressure applied to the module case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If repeated charging and discharging is used to simulate battery cell swelling, then the pressure test reflects actual battery behavior, but the testing time becomes excessively long
Solution Approach 1:
The patent replaces the electrochemical charging/discharging process with a direct mechanical pressing system. A pressing device applies controlled mechanical force to the battery cell to simulate the swelling effect, eliminating the need for repeated charge/discharge cycles. This substitution reduces testing time from multiple charge/discharge cycles to a single or few pressing operations while maintaining the simulation of actual swelling pressure.
Solution Approach 2:
The pressing device pre-calculates and directly applies the target pressure that would result from full charging, bypassing the gradual swelling process. By performing the pressure application in advance and directly, the system eliminates the time-consuming intermediate steps of charging and gradual expansion, achieving the same test objective more efficiently.
2Reliability
If repeated charging and discharging is used to simulate battery cell swelling, then the pressure test reflects actual battery behavior, but the control over pressure becomes difficult
Solution Approach 1:
The pressing device incorporates pressure sensors that provide real-time feedback on the applied force. This feedback loop allows the control system to monitor and adjust the pressing force to match the target pressure profile, ensuring precise control over the simulated swelling pressure. The system can maintain constant pressure or follow complex pressure patterns as required by the test specifications.
Solution Approach 2:
The pressing device features a dynamically controllable actuator that can adjust the pressing force in real-time according to a predetermined pressure profile. This dynamic control capability allows the system to simulate various swelling scenarios including constant pressure, increasing pressure, or cyclic pressure patterns, providing ease of operation and flexibility in test design.
3Device complexity
If a conventional pressure test device is used, then the structure is simple, but the pressure application lacks precision and control
Solution Approach 1:
The pressing device utilizes a hydraulic or pneumatic actuator to generate and control the pressing force. These fluid-based systems provide smooth, controllable, and precisely adjustable pressure output. The hydraulic/pneumatic system can maintain constant pressure with high accuracy and respond dynamically to control signals, achieving superior pressure control precision while keeping the overall device structure relatively simple.
Solution Approach 2:
The system introduces a pressure control unit as an intermediary between the actuator and the battery cell. This intermediary component includes pressure sensors, control valves, and a control algorithm that mediates the force transmission, ensuring precise pressure application. The intermediary layer adds minimal structural complexity while dramatically improving pressure control precision and repeatability.
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 approach allows for a rapid simulation of the pressure due to battery cell swelling, enabling the application of a desired pressure level and reducing the time required for testing while providing precise control over the pressure pattern, thereby improving the evaluation of welded portion fatigue.
Implementation Method 1
a pressure driver configured to apply a pressure to the pressure plate
Implementation Method 2
a pressure plate installed in a middle portion of the module case in a width direction and configured to pressure the battery cells toward the module case
Data Source
AI summary
A device is provided for performing a pressure test on a battery module. The device may include a module case in which battery cells are accommodated, a pressure plate installed in a middle portion of the module case in a width direction and configured to pressurize the battery cells toward the module case, a pressure driver configured to apply a pressure to the pressure plate, and a controller configured to control a pressure force and a pressure pattern with respect to the battery cells. The pressure plate may be configured to simulate expansion and contraction of the battery cells by repeatedly pressurizing and depressurizing the battery cells.