Battery Pack Stress Detection via Acceleration and Piezoelectric Sensors
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Solution Overview
Problem
Modern power tools and batteries can withstand mechanical stress and abuse but it is difficult for users to determine if they have been damaged, posing a safety risk when continuing to operate the system after exposure to mechanical stress or strain.
Innovation Solution
A system comprising a power tool and battery with acceleration sensors for detecting acceleration values in X, Y, and Z directions, piezoelectric sensors, a controlling device, signal transmitter, and voltage measurement device to determine vibrations, drops, impacts, and voltage changes, sending signals to indicate potential damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the system continues operating after mechanical stress, then productivity is maintained, but safety and reliability deteriorate due to potential undetected damage
Solution Approach 1:
The system performs preliminary detection of mechanical stress events (drops, impacts, shocks) using acceleration sensors and piezoelectric sensors before damage occurs. By detecting and recording these events in advance, the system can evaluate potential damage and alert users before operating in a compromised state, thus maintaining both productivity and reliability.
Solution Approach 2:
The system implements feedback by continuously monitoring acceleration values and piezoelectric sensor signals, evaluating whether mechanical stress thresholds are exceeded, and providing real-time alerts to users. This feedback loop enables users to stop operation when damage is detected, preventing further degradation while maintaining productivity during normal operation.
2Measurement precision
If multiple sensors and monitoring functions are added, then detection precision and safety are improved, but device complexity increases
Solution Approach 1:
The system merges multiple sensing functions into a unified monitoring structure. Acceleration sensors and piezoelectric sensors are integrated to detect different aspects of mechanical stress (drops, impacts, shocks), and their signals are processed together by a single controlling device. This combining approach improves measurement precision while managing device complexity through functional integration.
Solution Approach 2:
The controlling device serves multiple functions: it processes signals from both acceleration sensors and piezoelectric sensors, evaluates different types of mechanical stress, determines damage levels, and provides user alerts. This multi-functionality allows the system to achieve comprehensive detection precision without proportionally increasing device complexity, as one component performs multiple evaluation tasks.
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 system effectively monitors and alerts users to potential mechanical stress, enabling safer operation by distinguishing between non-harmful and harmful conditions, thus preventing potential hazards from undamaged power tools and batteries.
Implementation Method 1
at least one piezoelectric sensor
Implementation Method 2
at least one acceleration sensor for detecting at least one acceleration value in an X, Y and Z direction
Data Source
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AI summary
A method for controlling a system comprising a power-tool and a battery having energy storage cells, wherein the system comprises an acceleration sensor, a piezoelectric sensor, a controlling device, signal transmitter and a device for measuring a voltage. Method comprises the steps: - Determining vibration values acting upon the system by detecting accelerations values within a predetermined range; - Determining that the system is free-falling by detecting an acceleration value in the X, Y and Z direction being equal to a predetermined range; - Determining an impact of the system by detecting an acceleration value in the X, Y and Z direction exceeding a first predetermined threshold value; - Determine a traveling distance between detecting an acceleration value in the X, Y and Z direction being equal to a predetermined range and detecting an acceleration value in the X, Y and Z direction exceeding the first predetermined threshold value; - Determining a shock value by means of the piezoelectric sensor or the acceleration sensor; - Detecting a first and second voltage value by means of the device for measuring a voltage; and - Sending out a first signal if the accelerations values within the predetermined range for determining vibrations exceed a first predetermined threshold value for a first predetermined time period, the determined drop height exceeds a first predetermined threshold value, the detected value for determining a shock exceeds a first predetermined threshold value or a difference value between the first and second voltage value exceeds a first predetermined threshold value. A system for carrying out the method comprising a power-tool and at least one battery having at least one energy storage cell with an acceleration sensor, a controlling device, an interface for an exchange of data, a piezoelectric sensor, a signal transmitter and the power tool and a device for measuring a voltage.