Battery Monitoring PCB and Wire Harness for Open-Channel Voltage Sensing
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Solution Overview
Problem
Existing battery monitoring circuits face challenges in measuring cell voltages when top voltage sensing channels are open, requiring changes in hole size and wire dimensions, limiting their applicability to a wide range of battery modules.
Innovation Solution
A circuit board design that satisfies the constraint condition of battery monitoring circuits by using a relay conducting pattern and relay board terminals, allowing connection without altering hole size or wire dimensions, and a wire harness that facilitates voltage measurement across multiple battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the battery monitoring circuit uses a fixed number of voltage sensing channels to cover a wide range of battery modules, then the adaptability is improved, but the device complexity increases due to requiring more sensing channels than needed
Solution Approach 1:
The circuit board is designed with a fixed number of voltage sensing channels (e.g., 14 channels) that can universally accommodate battery modules with different numbers of cells (e.g., 12 cells). The extra channels remain open or unused, allowing the same circuit board design to work across multiple battery configurations without requiring custom designs for each battery type.
2Measurement precision
If the wire harness is designed to connect all voltage sensing channels, then the measurement precision is improved, but the manufacturing cost and complexity increase due to requiring additional wires and connection terminals
Solution Approach 1:
The wire harness is designed to connect only the necessary number of voltage sensing channels required for the specific battery module configuration. For example, when monitoring 12 battery cells, only 12 voltage sensing channels are actively connected through the wire harness, while the remaining channels are left open. This extracts the essential measurement paths while eliminating unnecessary wires and connection terminals, reducing manufacturing complexity and cost.
3Ease of manufacture
If the circuit board is customized for each battery module specification, then the ease of manufacture is improved, but the adaptability decreases limiting the circuit board to a single battery configuration
Solution Approach 1:
A single standardized circuit board design with a fixed number of voltage sensing channels and corresponding board terminals is used to manufacture multiple battery modules with different numbers of cells. The circuit board maintains sufficient sensing channels to cover the maximum expected battery configuration, allowing the same manufactured board to be applied universally across different battery module types without requiring custom manufacturing for each specification.
Data Source
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AI summary
Disclosed are a circuit board for a battery monitoring circuit and a wire harness for connection therewith. The battery monitoring circuit includes first to (M+1)-th voltage sensing pins, and has an operating condition that a voltage is applied to (M-N+1) to (M+1)-th voltage sensing pins among the first to (M+1)-th voltage sensing pins. The circuit board includes first to (M+1)-th conducting patterns formed electrically separably from each other, and electrically connected, at an end, to the first to (M+1)-th voltage sensing pins, respectively, a relay conducting pattern, wherein an end of the relay conducting pattern is electrically connected to (M-N+1)-th conducting pattern electrically connected to the (M-N+1)-th voltage sensing pin among the first to (M+1)-th conducting patterns, first to (M+1)-th board terminals, each of the first to (M+1)-th board terminals being electrically connected to an opposite end of each of the first to (M+1)-th conducting patterns, and a relay board terminal electrically connected to an opposite end of the relay conducting pattern. M is a natural number of 3 or greater, and N is a natural number of less than M.