Traction Battery Cell Sensor Welding for Accurate Temperature Monitoring
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Solution Overview
Problem
Existing methods for producing traction batteries in motor vehicles are costly and inefficient, particularly in achieving accurate temperature measurement across multiple battery cells.
Innovation Solution
Each battery cell in the traction battery is equipped with a separate temperature sensor mounted on a metal carrier, which is then welded to the cell housing, ensuring accurate and reliable temperature measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If each battery cell is equipped with a separate temperature sensor using known fastening methods, then temperature measurement capability is provided, but manufacturing cost increases and heat transfer is impaired over time
Solution Approach 1:
A metal carrier is introduced as an intermediary component between the temperature sensor and the battery cell housing. The temperature sensor is fastened to the metal carrier, which is then welded to the cell housing. This intermediary structure improves thermal contact and measurement accuracy while enabling efficient manufacturing through standardized welding processes.
2Measurement precision
If each battery cell is equipped with a separate temperature sensor using known fastening methods, then temperature measurement capability is provided, but heat transfer between the battery cell and temperature sensor deteriorates with age
Solution Approach 1:
The metal carrier serves as a thermal intermediary that maintains stable heat transfer between the battery cell housing and the temperature sensor. The welded connection of the metal carrier to the housing provides a durable thermal pathway that does not deteriorate with age, ensuring consistent measurement reliability throughout the battery's service life.
Solution Approach 2:
The solution employs a composite structure combining the metal carrier (with high thermal conductivity) and the temperature sensor mounting interface. This composite approach optimizes both thermal transfer efficiency and mechanical stability, preventing degradation of heat transfer properties over time.
3Quantity of substance
If multiple cell modules are arranged in the battery housing, then battery capacity is increased, but production complexity increases
Solution Approach 1:
The battery system is segmented into multiple modular cell modules, each independently assembled and then integrated into the battery housing. This segmentation allows for standardized production of individual modules, reducing overall production complexity while achieving high battery capacity through modular scaling.
Solution Approach 2:
The metal carrier and temperature sensor assembly is designed as a universal component that can be applied to each cell module in the same standardized manner. This universality simplifies production processes across multiple modules, allowing identical procedures to be repeated for each module rather than requiring custom solutions.
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 method allows for rapid, inexpensive production of traction batteries with precise temperature monitoring, enhancing operational efficiency and durability.
Implementation Method 1
at least one temperature sensor is arranged on a metal carrier in each case and the metal carrier is welded to a cell housing of the respective battery cell
Implementation Method 2
the metal carrier is welded to a cell housing of the respective battery cell
Data Source
AI summary
A method for producing a traction battery of a motor vehicle. At least one cell module having multiple battery cells is arranged in a receptacle compartment of a battery housing of the traction battery. The battery cells are provided with a separate temperature sensor At least one temperature sensor is arranged on a metal carrier in each case and the metal carrier is welded to a cell housing of the respective battery cell.