Battery Pack Line Open Detection and Protection Circuit
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Solution Overview
Problem
Battery packs in portable power tools often lack an over-discharge controller, leading to reduced reliability and increased risk of defects due to uncontrolled charging and discharging operations.
Innovation Solution
A battery pack configuration that includes a control unit and a protection circuit unit, which detects line open conditions in connection lines and prevents further charging and discharging by opening the protection circuit when a line open condition is detected, ensuring safe operation and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an over-discharge controller is installed in the battery pack, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges the over-discharge protection function with the existing connection lines between battery cells. The control unit utilizes the existing connection line structure to detect line open conditions, combining multiple functions (over-discharge protection and line open detection) into a unified system rather than adding separate independent components.
Solution Approach 2:
The connection lines between battery cells serve dual purposes: they connect the battery cells electrically and simultaneously function as sensing lines for detecting line open conditions. This multi-functional design eliminates the need for separate sensing components, reducing overall system complexity while maintaining reliability.
2Manufacturing precision
If line open detection is implemented, then manufacturing defects are reduced, but device complexity increases
Solution Approach 1:
The battery pack system performs self-diagnosis by using its own connection lines to detect line open conditions. The control unit monitors the voltage differences across battery cells through the existing connection lines, enabling the system to self-identify manufacturing defects without requiring external testing equipment or complex additional sensing systems.
Solution Approach 2:
The line open detection function is activated during the manufacturing process to identify defective battery packs before shipment. The control unit performs voltage measurements and comparisons in advance to detect potential line open conditions, allowing defective products to be filtered out before reaching customers.
3Reliability
If the protection circuit unit is opened to prevent harmful operations, then reliability is improved, but productivity decreases
Solution Approach 1:
The control unit continuously monitors the voltage differences between battery cells and compares them against predetermined thresholds. When a line open condition is detected through this feedback mechanism, the control unit automatically opens the protection circuit unit to prevent harmful operations, ensuring safety while maintaining normal operation under healthy conditions.
Solution Approach 2:
The control unit acts as an intermediary between the battery cells and the protection circuit unit. It monitors the connection lines and mediates by opening or closing the protection circuit based on detected conditions, balancing safety requirements with operational continuity.
Data Source
AI summary
A battery pack and a method of operating the battery pack are disclosed. The battery pack includes a plurality of battery cells and is configured to open a terminal of the battery if an open circuit is detected in a line connecting battery cells.