Battery Pack Module Disconnection via Sensor-Controlled Relays
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Solution Overview
Problem
Battery packs used in high-power applications like electric vehicles and hybrid vehicles face safety risks due to potential electrical failures from impacts or moisture, which can lead to increased output voltage and risk of fire or electric shock, as existing systems lack effective mechanisms to safely disconnect electrical connections between modules.
Innovation Solution
A battery pack design that includes a battery control unit connected to sensors and relays, allowing for the controlled disconnection of electrical connections between modules in response to impact or moisture detection, thereby reducing voltage to a safe level and preventing electrical shocks or fires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery modules are electrically connected to increase power and capacity, then output voltage and current are improved, but the risk of electrical failure from impacts or moisture increases
Solution Approach 1:
The battery pack is divided into multiple battery modules that can be electrically connected in series or parallel to achieve desired power levels. Each module is a separate unit that can be independently managed and disconnected through relays, allowing the system to maintain high power output while enabling selective isolation of damaged modules to prevent system-wide failures.
Solution Approach 2:
Relays are introduced as intermediary components between battery modules to control electrical connections. These relays act as safety intermediaries that can quickly disconnect modules when sensors detect impacts or moisture, preventing electrical failures from propagating through the entire battery pack while allowing normal operation when conditions are safe.
2Reliability
If relays are added to disconnect battery modules for safety, then safety risk is reduced, but device complexity increases
Solution Approach 1:
The relays are designed to serve multiple functions: they enable normal electrical connection between battery modules for high power output, provide rapid disconnection for safety when sensors detect impacts or moisture, and allow for modular repair and maintenance. This multi-functionality reduces the need for separate safety systems and simplifies the overall device architecture.
Solution Approach 2:
The battery control unit automatically monitors sensor inputs and controls the relays without requiring external intervention. When sensors detect impacts or moisture, the system self-activates the relays to disconnect damaged modules, providing autonomous safety protection that reduces the need for complex manual override circuits or additional control layers.
3Reliability
If sensors and control circuits are added to detect damage and control relays, then safety is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The sensor inputs and relay control functions are merged into a single battery control unit that manages both detection and actuation. This integration reduces the need for separate control circuits and minimizes the number of discrete components, simplifying manufacturing processes and reducing assembly complexity while maintaining comprehensive safety monitoring and control capabilities.
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
The solution effectively reduces the risk of electrical shocks and fires by safely disconnecting electrical connections between battery modules when damage is detected, enhancing the safety of battery packs in high-power applications.
Implementation Method 1
a relay connected to output lines of the plurality of battery modules and at least one connection line between battery modules of the plurality of battery modules
Data Source
AI summary
A battery pack including a plurality of battery modules including a plurality of battery cells; a plurality of relays connected to output lines of the plurality of battery modules and at least one connection line between battery modules of the plurality of battery modules; a battery control unit connected to the plurality of relays for controlling the plurality of battery cells; and at least one sensor connected to the battery control unit and configured to output a signal to the battery control unit, and the battery control unit is configured to control the plurality of relays in response to the signal outputted from the at least one sensor.