Battery Sensor Temperature Measurement via Contact Elements
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Solution Overview
Problem
Current battery sensors in vehicles face challenges in accurately measuring currents and temperatures due to the temperature dependence of copper alloys used in connection elements and measuring resistors, leading to complex and expensive temperature measurement methods.
Innovation Solution
A battery sensor design with two current measuring devices and temperature sensors connected to separate contacts on each connection element, allowing for precise temperature measurement and detection of temperature distribution across the measuring resistor and connection elements, enabling accurate current measurement even with materials having high temperature dependence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are placed on the measuring resistor to improve temperature measurement accuracy, then measurement precision is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent introduces contact elements as intermediary components that thermally connect the measuring resistor to the circuit board. These contact elements serve as heat transfer mediators, allowing temperature information to be transmitted from the measuring resistor to temperature sensors located on the circuit board, thereby avoiding direct placement of sensors on the measuring resistor while maintaining measurement accuracy
Solution Approach 2:
The patent replaces direct mechanical/physical contact of temperature sensors with the measuring resistor by using thermal conduction through contact elements and circuit board traces. This substitution moves the sensing mechanism from direct contact to indirect thermal field measurement, reducing structural complexity
2Ease of manufacture
If copper alloys are used in connection elements for ease of manufacture and electrical conductivity, then ease of manufacture is improved, but temperature dependence of electrical resistance increases
Solution Approach 1:
The patent compensates for the temperature dependence of copper alloy electrical resistance by measuring temperature and applying correction algorithms. The electrical resistance values are adjusted based on measured temperature data and known temperature-coefficient relationships, transforming the resistant temperature dependence into a correctable parameter
Solution Approach 2:
The patent implements a feedback mechanism where temperature sensors continuously monitor the temperature of connection elements and measuring resistors, and this temperature information is fed back to the evaluation circuit to compensate for temperature-induced resistance changes, thereby maintaining measurement precision despite using temperature-sensitive copper alloys
3Measurement precision
If multiple temperature sensors are added to measure temperature distribution across connection elements, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent makes the contact elements serve multiple functions: they provide electrical connection, mechanical support, and thermal conduction pathways. By utilizing the existing contact elements and circuit board traces for thermal conduction, the system can use fewer dedicated temperature sensors while still achieving temperature distribution measurement through strategic sensor placement on the circuit board
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 design enhances the accuracy of current measurement by precisely determining the temperature and electrical resistance of connection elements and measuring resistors, allowing for error detection and compensation of thermal voltages, thereby improving overall measurement precision.
Implementation Method 1
a first temperature sensor which is thermally connected to the first contact or the second contact
Implementation Method 2
the current strength is determined via the voltage drop across a measuring resistor arranged in the current path
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to a battery sensor (10) for a vehicle, wherein the battery sensor (10) has a measuring resistor (24) arranged between a first connection element (26) and a second connection element (28) and electrically contacted with them. At least two first contacts (40a, 40b) are provided on the first connection element (26) and at least two second contacts (42a, 42b) are provided on the second connection element (28). A first measuring device (33a) with a first current measuring device (34a) and a second measuring device (33b) with a second current measuring device (34b) are provided, wherein the current measuring devices (34a, 34b) are each electrically contacted with a first contact (40a, 40b) and a second contact (40a, 40b).The first measuring device (33a) has a first temperature sensor (44a) and the second measuring device (33b) has a second temperature sensor (44b), each of which is thermally connected to a first contact (40a, 40b) or a second contact (42a, 42b). An evaluation circuit (32) is connected to the first measuring device (33a) and the second measuring device (33b) for evaluating the temperature signals output by the temperature sensors (44a, 44b).