EV Battery Pack Vibration Inspection for Early Failure Detection
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Solution Overview
Problem
Current inspection methods for EV battery packs are often time-consuming, labor-intensive, and invasive, leading to undetected early failures and premature replacements, which pose financial and performance concerns.
Innovation Solution
A non-destructive inspection (NDI) scheme that uses a mechanical excitation probe to vibrate an exterior surface of an EV, generating an excitation signal that passes through the battery pack, and is measured by differential sensor probes, allowing for the detection of performance-related properties without damaging the battery pack or EV.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection methods are used for EV battery packs, then inspection can be performed, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated acoustic emission detection system. Sensors electronically detect and analyze acoustic signals from battery cells, substituting human operators with an automated electronic detection and analysis system that processes data rapidly without manual intervention.
Solution Approach 2:
The battery pack inspection system enables the battery pack itself to indicate its condition through acoustic emission signals. The battery cells naturally generate acoustic emissions during operation that reveal their health status, eliminating the need for external active testing or disassembly, and allowing the inspected object to provide its own diagnostic information.
2Measurement precision
If invasive inspection methods are used, then internal defects can be detected, but the battery pack requires disassembly which introduces additional time and labor
Solution Approach 1:
The patent replaces physical disassembly with electronic acoustic emission detection. Sensors placed on the battery pack exterior electronically penetrate and detect internal cell conditions through acoustic signals, substituting mechanical disassembly with non-contact electronic sensing that achieves internal inspection without physical intrusion.
Solution Approach 2:
The patent uses acoustic emission signals as an intermediary to transmit information from the internal battery cell state to external sensors. The acoustic waves serve as a mediator that carries diagnostic information through the battery pack structure, allowing internal condition assessment without direct physical access or disassembly of internal components.
3Reliability
If current inspection methods are used, then some defects can be detected, but early failures remain undetected leading to premature replacements
Solution Approach 1:
The patent implements continuous acoustic emission monitoring that provides real-time feedback on battery cell health. The system constantly detects acoustic signals during battery operation and analyzes them to identify early signs of cell degradation or failure, enabling proactive maintenance decisions based on actual condition data rather than scheduled maintenance.
Solution Approach 2:
The patent enables preliminary detection of battery cell failures through continuous acoustic monitoring before actual failure occurs. By detecting acoustic emission patterns that precede cell failure, the system allows for early intervention and replacement planning, preventing complete failure and optimizing maintenance timing to avoid premature replacements.
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
This NDI scheme effectively detects failure modes in EV battery packs without disassembly, improving maintenance and longevity, thereby supporting the growth of the EV market and reducing reliance on fossil-fuel vehicles.
Implementation Method 1
positioned in contact with an exterior facing surface of an EV and vibrating the surface such that an excitation signal corresponding to the vibrating passes through the battery pack of the EV
Implementation Method 2
Excitation data associated with the excitation signal after it passes through the battery pack is collected by differential sensor probes positioned a predetermined distance from the mechanical excitation probe
Data Source
AI summary
A method and system for applying non-destructive inspection tests to battery packs of electronic vehicles (EV) is disclosed herein. A mechanical shaker is positioned below a subject EV and vibration input is applied to the battery pack at the base of the EV. Differential vibration sensors read output of the mechanical shaker as passed through the battery pack. Variations in the resultant vibration output are indicative of any of a number of failure modes that are trained into an AI model that analyzes the detected vibration output. Example apparatus for positioning the testing apparatus under the EV include a rover or a motorized undercarriage gantry.