Battery Terminal Post Sizing Using Thermal Simulation
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Solution Overview
Problem
The existing methods for determining the size of a cell terminal post in prismatic cells are inaccurate and time-consuming, leading to inefficiencies in reducing temperature rise due to overcurrent and affecting cell performance.
Innovation Solution
A method and apparatus that utilize a thermal simulation model to determine the size of a cell terminal post by establishing a cell structural model, inputting pre-determined initial sizes into a thermal simulation model, and calculating temperature data to accurately determine target sizes based on relative temperature differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If orthogonal experiment is used to determine terminal post size, then design process is simple, but determination accuracy is low and design cycle is long
Solution Approach 1:
The patent pre-establishes a thermal simulation model before the design process begins. This model includes pre-defined material properties, geometric parameters, and thermal boundary conditions for the terminal post and surrounding components. By preparing the simulation framework in advance with multiple pre-determined initial sizes, the system eliminates the need for repeated model building during iterative design, thus reducing design cycle time while maintaining high determination accuracy through systematic thermal analysis.
Solution Approach 2:
The patent replaces the traditional orthogonal experiment method (mechanical/physical testing approach) with a thermal simulation model (computational approach). Instead of physically manufacturing and testing multiple terminal post variants to determine optimal sizes, the system uses computer-based thermal field simulation to predict temperature distribution and determine the optimal terminal post size. This substitution dramatically reduces both time consumption and material waste while improving determination accuracy through controlled virtual experimentation.
2Measurement precision
If manual operations are performed in design cycle, then flexibility is maintained, but determination accuracy decreases
Solution Approach 1:
The thermal simulation model is designed to automatically perform the complete determination process without manual intervention. The system automatically inputs pre-determined initial terminal post sizes, executes thermal field simulation, processes temperature distribution data, and outputs the determined terminal post size based on predefined criteria. This automation eliminates manual measurement and calculation errors, ensuring high determination accuracy. The system self-manages the entire workflow from input to output, reducing reliance on operator skill and consistency.
Solution Approach 2:
The patent implements a feedback mechanism where the thermal simulation model continuously monitors temperature distribution in the thermal field and adjusts the determination process accordingly. The system compares simulated temperature data against target temperature requirements and uses this feedback to refine the terminal post size determination. This closed-loop feedback ensures high accuracy by iteratively optimizing the solution based on actual thermal performance predictions, while the automated feedback processing reduces the need for complex manual analysis procedures.
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
Improves the accuracy of determining terminal post sizes, reducing temperature rise in structural components and enhancing cell performance by using thermal simulation to optimize terminal post dimensions.
Implementation Method 1
input the cell structural model and each of the multiple pre-determined initial terminal-post sizes into a pre-built thermal simulation model for thermal simulation processing, to obtain temperature data
Data Source
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AI summary
A method for determining a size of a cell terminal post is provided in the disclosure. The method includes the following. A cell structural model of a cell is established, where the cell structural model includes a terminal-post model of the terminal post, and the terminal-post model has multiple pre-determined initial terminal-post sizes. The cell structural model and each of the multiple pre-determined initial terminal-post sizes are input into a pre-built thermal simulation model for thermal simulation processing, to obtain temperature data for each of the multiple pre-determined initial terminal-post sizes. All target terminal-post sizes of the terminal post are determined.