Battery Overcurrent Protection System with Shunt Resistor
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Solution Overview
Problem
Existing overcurrent protection systems for lithium battery systems are costly and have slow response times, with protection characteristic curves that can lead to false activation or destruction of components due to high currents and complex operating conditions.
Innovation Solution
A protection system with an acquisition unit using a shunt resistor to determine current intensity, an electronic processing unit for comparing this information with an adaptable protection specification, and a protection element that can be irreversibly activated to interrupt the current path, providing flexible and efficient overcurrent protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an irreversible protection such as a fuse is used for overcurrent protection, then the current flow can be prevented in the event of an overcurrent, but the protection is relatively costly and has slow response time
Solution Approach 1:
The patent replaces the mechanical/thermal protection mechanism of a fuse with an electronic protection system that uses a shunt resistor for current measurement, a processing unit for real-time analysis, and an electronic switch for rapid disconnection. This substitution enables much faster response times while maintaining reliable overcurrent protection.
Solution Approach 2:
The patent introduces a shunt resistor as an intermediary element in the current path to measure current without interrupting the flow. This allows the processing unit to continuously monitor current conditions and trigger protection only when necessary, achieving fast response without the inherent delays of thermal or magnetic fuse mechanisms.
2Reliability
If a protection with high switch-off capacity is selected to prevent short circuits, then short circuit protection is improved, but the cost increases significantly
Solution Approach 1:
The patent segments the protection function into separate components: a low-cost shunt resistor for measurement, a processing unit for intelligence, and an electronic switch for execution. This segmentation allows each component to be optimized independently, replacing the need for an expensive high-capacity fuse with multiple lower-cost specialized components.
Solution Approach 2:
The patent changes the operating parameters of the protection system by using electronic control rather than passive thermal/magnetic mechanisms. The electronic switch can be controlled to provide high switch-off capacity on demand, rather than requiring the protection device itself to have high capacity throughout, thereby reducing overall system cost.
3Reliability
If the protection characteristic curve is adjusted to activate at higher currents, then false activation is reduced, but other components in the current path may be destroyed by high currents
Solution Approach 1:
The patent performs preliminary action by continuously monitoring current through the shunt resistor before dangerous conditions develop. The processing unit analyzes current trends and can trigger protection at lower threshold values with hysteresis logic, preventing both false activation and component damage by acting preemptively rather than reactively.
Solution Approach 2:
The patent introduces dynamic behavior through the processing unit, which can adapt protection thresholds based on operating conditions, temperature, and current history. This dynamic adjustment allows the system to distinguish between normal transient overcurrents and genuine faults, preventing false activation while protecting components from damaging currents.
4Adaptability or versatility
If multiple protection devices are added to cover different operating ranges, then protection coverage is improved, but the device complexity increases
Solution Approach 1:
The patent creates a universal protection system where the shunt resistor, processing unit, and electronic switch work together to handle all protection scenarios. The processing unit implements multiple protection characteristics through software/algorithms, eliminating the need for multiple physical protection devices while maintaining comprehensive coverage across different operating ranges.
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 reliable and fast activation of overcurrent protection, reducing costs and component damage by allowing adjustable activation characteristics and eliminating the need for additional fuses, while ensuring flexible adaptation to various applications and operating ranges.
Implementation Method 1
an acquisition unit (in particular having a shunt resistor which is integrated in the current path) for determining (at least) acquisition information which is specific at least for one electrical current of the current path
Data Source
AI summary
A protection system for overcurrent protection in a battery system. The protection system can have a protection element for interrupting an electric current path in the battery system. The protection system can have an acquisition unit for determining acquisition information which is specific for an electric current of the current path. The protection system can have an electronic processing unit for performing a comparison of the acquisition information with an adaptable protection specification to detect an overcurrent condition. The electronic processing unit can be operatively connected to the protection element to activate the protection element in response to the comparison such that the interruption occurs upon positive detection of the overcurrent condition in accordance with an adjustable activating characteristic.