Battery Connection String Fault Detection Using Injected Test Current
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Solution Overview
Problem
Existing battery systems face challenges in accurately measuring cell voltages due to fluctuations in cell capacity and resistance caused by manufacturing tolerances and aging, which can lead to inaccurate charge distribution and potential electrical connection issues, necessitating early detection of adverse electrical changes.
Innovation Solution
A module comprising a control unit, current sources, and sensor units is used to detect string faults in the electrical connections between circuit units and battery cells by measuring test voltages and differential voltages, ensuring reliable electrical connections for accurate voltage measurements and even charge distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical connections are monitored to detect adverse changes, then reliability of voltage measurement is improved, but device complexity increases due to additional monitoring components
Solution Approach 1:
The circuit unit performs multiple functions: it measures battery cell voltages, distributes charge evenly, and monitors electrical connection integrity. By integrating these functions into a single unit, the patent avoids adding separate monitoring systems, thus improving reliability without proportionally increasing device complexity
Solution Approach 2:
The circuit unit monitors its own electrical connections by measuring voltages during normal operation. This self-diagnostic capability allows the system to detect connection issues without external monitoring equipment, maintaining reliability improvement while minimizing additional complexity
2Reliability
If circuit units are used for even charge distribution, then battery cell protection is improved, but device complexity increases due to additional circuit components
Solution Approach 1:
The circuit unit simultaneously provides charge distribution, voltage measurement, and connection monitoring functions. This multi-functionality allows the system to achieve comprehensive battery protection without adding separate dedicated systems for each function, thereby limiting the increase in device complexity
3Measurement precision
If electrical resistance changes are monitored to detect connection faults, then measurement precision is improved, but loss of energy increases due to continuous monitoring current
Solution Approach 1:
The circuit unit monitors electrical connections by periodically measuring voltages during normal battery operation rather than continuously dedicating separate monitoring current. This approach maintains measurement precision for detecting connection faults while minimizing energy loss by utilizing existing operational cycles
Solution Approach 2:
The monitoring function is integrated into the normal charge/discharge operations, allowing the system to continuously assess connection integrity without adding separate energy-consuming monitoring cycles. The same current paths used for battery operation are utilized for monitoring purposes
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
The module effectively detects string faults, ensuring reliable electrical connections and accurate voltage measurements, thereby maintaining efficient charge distribution across battery cells, facilitating timely repairs and preventing further damage.
Implementation Method 1
controlling a first current source to cause a first current through the first module string and the first connection string
Implementation Method 2
detecting, while the first current is flowing, a first test voltage between a first module node and a second module node
Data Source
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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.