Battery Monitoring PCB Relay Layout for Open Sensing Channels
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Solution Overview
Problem
Existing battery monitoring circuits face operational constraints when certain voltage sensing channels are open, leading to incomplete cell voltage measurement, and current solutions require complex modifications to wire harnesses and circuit boards to meet these constraints.
Innovation Solution
A circuit board design with separable conducting patterns and relay connections allows for voltage sensing channels to operate under constraints without altering wire harness dimensions or hole sizes, enabling complete cell voltage measurement across a wide range of battery modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If voltage sensing channels are left open to accommodate fewer battery cells, then the circuit board can be designed with fixed specifications, but the battery monitoring circuit cannot operate properly due to constraint conditions requiring a predetermined number of voltage sensing channels to be connected
Solution Approach 1:
A relay circuit is introduced as an intermediary component between the wire harness and the battery monitoring circuit. The relay circuit includes relay switching elements that can selectively connect or disconnect voltage sensing channels based on the actual number of battery cells, thereby mediating between the fixed circuit board design and the variable battery module configurations while ensuring the battery monitoring circuit operates under its constraint conditions
Solution Approach 2:
The relay circuit provides dynamic reconfigurability to the voltage sensing system. The relay switching elements can change the connection state of voltage sensing channels in real-time based on the detected number of battery cells, transforming a static circuit board design into a dynamically adaptable system that satisfies both manufacturing simplicity and operational reliability
2Adaptability or versatility
If the circuit board is designed with a large number of voltage sensing channels for wide coverage, then it can accommodate different battery module configurations, but the device complexity increases
Solution Approach 1:
The relay circuit serves multiple functions: it acts as a switch for voltage sensing channels, a detector for the number of battery cells, and a controller for configuring the sensing paths. This multi-functionality allows a single relay circuit module to handle various battery module configurations without requiring different circuit board designs, thereby achieving universality without proportionally increasing complexity
3Reliability
If wire harness dimensions and hole sizes are modified to meet battery monitoring circuit constraints, then the circuit can operate properly, but the manufacturing cost and complexity increase
Solution Approach 1:
The electrical connection system is segmented into three independent components: the wire harness, the relay circuit, and the circuit board. Each component maintains its original design specifications without requiring modifications to dimensions or hole sizes. The relay circuit acts as an independent intermediary that bridges the wire harness and circuit board, eliminating the need for coordinated modifications across all components and thereby maintaining ease of manufacture while ensuring proper operation
Data Source
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, operating on a 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 each of 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.