Redundant Battery Pack Management for eVTOL Fault Isolation

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Solution Overview

Problem

The challenge of achieving high energy density in electric aircraft power sources is critical for eVTOL aircraft, as existing technologies struggle to pack maximum energy in the lightest possible configuration, complicating manned and unmanned flight.

Innovation Solution

A battery management system integrated in a battery pack with redundant first and second battery management components, each with its own sensor suite, data storage, and isolation mechanisms to ensure continuous operation and data integrity, monitoring and managing battery health and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If redundant battery management components are implemented, then reliability is improved, but device complexity increases

Engineering Contradiction:
Improvebattery management reliabilityVSAvoidbattery management system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The battery management system is divided into multiple independent management components, each capable of autonomous operation. Each component has its own sensor suite and data storage, allowing the system to segment monitoring functions across multiple units for enhanced reliability without requiring a single complex centralized system.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Each battery management component is equipped with localized sensor suites and data storage capabilities specific to its monitoring zone. This local quality approach allows each component to independently manage its portion of the battery pack while maintaining overall system reliability through distributed intelligence.

Inventive Principle:
Principle #3Local quality

2Measurement precision

If multiple sensor suites are deployed, then measurement precision is improved, but device complexity increases

Engineering Contradiction:
Improvebattery pack data measurement precisionVSAvoidsensor system complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The sensor suites are segmented and distributed across multiple battery management components rather than centralized in one location. Each component has its own sensors for measuring battery pack data, which improves measurement precision through distributed monitoring while managing complexity through modular architecture.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Multiple identical sensor suites are deployed across different battery management components. Each sensor suite is a copy of the others, measuring the same battery pack parameters independently. This copying approach ensures consistent measurement precision across the system while using standardized, manageable sensor designs.

Inventive Principle:
Principle #26Copying

3Loss of information

If data storage capacity is increased, then information retention is improved, but weight increases

Engineering Contradiction:
Improvebattery pack data retentionVSAvoidbattery pack weight
Core Design Contradiction:
Loss of informationVSWeight of moving object

Solution Approach 1:

Data storage is segmented across multiple battery management components rather than using a single large storage system. Each component has its own data storage capability, which collectively provides comprehensive data retention while distributing the weight burden across multiple lighter storage units within the battery pack.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS12351064B2Systems and methods for a battery management system integrated in a battery pack configured for use in electric aircraft
Publication Date: 2025.07.08 BETA AIR LLC
  • US12351064B2 patent drawing
  • US12351064B2 patent drawing
  • US12351064B2 patent drawing

AI summary

A battery management system integrated in a battery pack configured for use in electric aircraft, the system comprising a first battery management component comprising a first sensor suite configured to measure a first plurality of battery pack data. The battery management system comprising a second battery management component comprising a second sensor suite configured to measure a second plurality of battery pack data. The battery management system comprising a data storage system configured to store the first plurality of battery pack data and the second plurality of battery pack data.