Battery Pack Fire Safety Test System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current battery pack test systems lack the capability to accurately determine how long a vehicle battery pack can contain a fire, which is crucial for ensuring fire safety in hybrid and electric vehicles.
Innovation Solution
A battery pack test system that includes a first battery charging device to charge the vehicle battery pack to a desired state-of-charge, a second battery charging device to overcharge a battery cell, a data acquisition computer to monitor output voltage and temperature, an electrically-actuated igniter to induce a spark, and video cameras to capture and analyze images for signs of fire and gas escape, triggering the igniter to generate a fire within the battery pack if voltage exceeds a threshold or gases are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery pack test system is designed to perform fire safety testing, then the ability to determine fire containment time is improved, but the device complexity increases due to multiple charging devices, video cameras, and control systems
Solution Approach 1:
The test system is divided into distinct functional modules: a first battery charging device for pack-level charging, a second battery charging device for cell-level overcharging, video cameras for visual monitoring, and a control system. This segmentation allows each component to perform its specific function efficiently while maintaining overall system reliability for fire safety testing.
Solution Approach 2:
The system performs preliminary charging actions to create specific test conditions before initiating the fire safety test. The first charging device charges the battery pack to a desired state of charge, and the second charging device subsequently overcharges specific cells to create the conditions necessary for fire testing, ensuring controlled and repeatable test scenarios.
2Measurement precision
If multiple monitoring devices are added to detect fire conditions, then the measurement precision of fire containment time is improved, but the device complexity and cost increase
Solution Approach 1:
The video cameras serve multiple functions: they monitor for gas escape from battery cells, detect fire conditions, and record the entire test process. This multi-functionality allows the system to achieve high measurement precision for fire containment time while avoiding the need for separate specialized sensors for each detection task, thereby controlling device complexity.
3Reliability
If the battery cell is overcharged to create fire conditions, then the fire safety test accuracy is improved, but the risk of unintended fire hazards increases
Solution Approach 1:
The system takes preliminary protective actions by implementing continuous monitoring through video cameras and control systems before and during the overcharging process. The control system is prepared to intervene and stop the test if abnormal conditions are detected, preventing unintended fire hazards while allowing accurate fire safety testing to proceed.
Solution Approach 2:
The control system acts as an intermediary between the second battery charging device and the battery cell. It carefully controls the overcharging process, monitors conditions in real-time, and can interrupt the process if necessary, thereby enabling accurate fire safety testing while mitigating the fire hazard risk associated with overcharging.
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
Enables the accurate assessment of a battery pack's ability to contain a fire for a predetermined time, providing critical fire safety data by simulating a fire scenario and monitoring its propagation within the battery pack.
Implementation Method 1
an electrically-actuated igniter disposed in the vehicle battery pack... a voltage is applied to the electrically-actuated igniter to induce the igniter to generate an electrical spark
Implementation Method 2
a first battery charging device configured to supply a first electrical current to the vehicle battery pack... a second battery charging device configured to supply a second electrical current to a battery cell
Data Source
AI summary
A battery pack test system is provided. The system includes a battery charging device that monitors an output voltage level of the vehicle battery pack. The system further includes a switch electrically coupled between an igniter and a voltage source. The system further includes a first video camera that generates a first plurality of images of an interior of the vehicle battery pack. The switch has a closed operational state at a first time in response to the output voltage level of a battery cell in the vehicle battery pack being greater than a threshold voltage level, to induce the igniter to generate a spark to generate a fire within an interior region of the vehicle battery pack.