Battery String Fault Detection via Test Current Voltage Sensing
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Solution Overview
Problem
Batteries with interconnected cells face issues due to manufacturing tolerances and aging, leading to fluctuations in cell capacity and resistance, which can cause inaccurate voltage measurements and uneven charge distribution, potentially exacerbated by adverse electrical changes in connections.
Innovation Solution
A module and method using a control unit, current sources, and sensor units to detect string faults in the electrical connections between circuit units and battery cells, ensuring accurate voltage measurements and even charge distribution by identifying high resistance or interruptions in these connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If circuit units are used to measure cell voltages and manage battery cells, then battery management and charge distribution are improved, but the system becomes vulnerable to electrical connection faults that can cause measurement errors and uneven charge distribution
Solution Approach 1:
The patent applies preliminary action by implementing a test current source that proactively tests electrical connections between circuit units and battery cells before normal operation. The system periodically injects test currents through the connections and measures the resulting voltages to detect faults in advance, preventing measurement errors and charge distribution issues before they occur during actual battery operation.
Solution Approach 2:
The patent uses an intermediary approach by introducing a test current source as a mediator to assess the health of electrical connections. This test current source acts as an intermediate element that temporarily connects to the battery cells through the same electrical paths used during normal operation, allowing indirect measurement of connection quality without interfering with the primary battery management functions.
2Ease of manufacture
If manufacturing tolerances and aging are accepted as inevitable, then production costs and battery lifespan are optimized, but fluctuations in cell capacity and resistance lead to inaccurate voltage measurements
Solution Approach 1:
The patent implements feedback by continuously monitoring the electrical connections between circuit units and battery cells using test currents and voltage measurements. The system compares measured values against expected ranges and provides feedback to the battery management system, allowing for real-time compensation and correction of measurement inaccuracies caused by manufacturing tolerances and aging effects.
3Reliability
If electrical connections are monitored continuously, then detection reliability is improved, but system complexity and energy consumption increase
Solution Approach 1:
The patent applies periodic action by implementing intermittent monitoring of electrical connections through scheduled test current injections. Instead of continuous monitoring, the system periodically activates the test current source at predetermined intervals to assess connection quality, reducing system complexity and energy consumption while maintaining adequate detection reliability for safety-critical applications.
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
Enables reliable and efficient detection of string faults, allowing for accurate voltage measurements and even charge distribution across battery cells, thereby maintaining battery performance and preventing adverse conditions.
Implementation Method 1
controlling a first current source (134) to generate a first current through the first module string (122)
Implementation Method 2
detecting by a first sensor unit (140) a test voltage between a first module node (124) and a second module node (130)
Implementation Method 3
detecting by a control unit (138) a first string fault in a first connection string (108) based on the test voltage
Data Source
AI summary
The present disclosure relates to module comprising a first module terminal for coupling to a first battery node of a battery via a first connecting string, a second module terminal for coupling to a second battery node of the battery via a second connection string, a base module terminal for coupling to a base battery node of the battery via a base connection string, wherein a first module string of the module extends from the first module terminal to a first module node of the module, wherein a second module string of the module extends from the second module terminal to a second module node of the module, wherein a first current source is coupled between the base module terminal and the first module node, wherein a control unit of the module is coupled to the first current source and is configured to control the first current source to activate a generation of a first current in the first module string via the first current source, wherein a first sensor unit of the module is coupled to the first and second module nodes, wherein the first sensor unit is configured to detect a first test voltage between the first module node and the second module node while the first current is flowing, and wherein the control unit is configured to detect a first string fault in the first connection string based on the first test voltage. The present disclosure also relates to a system including the module and a method for the module.