Battery Module Swelling Detection Using Existing Temperature Sensors
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Solution Overview
Problem
Conventional methods for detecting battery cell swelling require additional devices like pressure sensors or flow meters, increasing costs and reducing internal space efficiency, and are cumbersome to inspect and disassemble.
Innovation Solution
A system using first and second temperature measurement units within the battery module to determine swelling by measuring temperature and controlling a cooling fan, without the need for separate devices, by calculating temperature deviations and comparing them to predetermined values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional sensors (pressure sensors or flow meters) are installed in the battery module to detect swelling, then detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The cooling fan serves multiple functions: it cools the battery module during normal operation and acts as a detection mechanism for swelling by monitoring its operational status and temperature changes. This eliminates the need for separate detection devices while maintaining swelling detection capability.
Solution Approach 2:
The battery management system uses existing temperature sensors and cooling fan operation data to detect swelling, allowing the system to monitor its own health status without requiring external detection devices. The system leverages data already being collected for thermal management purposes.
2Measurement precision
If additional devices (flow meters or pressure sensors) are equipped in the battery module, then swelling detection is improved, but internal space utilization deteriorates
Solution Approach 1:
Existing temperature sensors and cooling fan components are repurposed for dual functions: thermal management during normal operation and swelling detection when abnormal temperature patterns are detected. This eliminates the need for additional space-consuming detection devices.
Solution Approach 2:
The system uses its existing infrastructure (temperature sensors and cooling fan) to perform self-diagnosis for swelling detection, eliminating the need for separate detection hardware that would occupy valuable internal space within the battery module.
3Measurement precision
If conventional inspection methods (disassembly and direct inspection) are used, then detection accuracy is improved, but inspection time and operational complexity increase
Solution Approach 1:
The system continuously monitors temperature data during normal battery operation, enabling early detection of swelling conditions before they become critical. This preliminary monitoring eliminates the need for time-consuming periodic disassembly inspections, as abnormalities are detected in real-time during normal use.
Solution Approach 2:
The system establishes a feedback loop where temperature sensor data and cooling fan operation status are continuously analyzed to detect swelling conditions. This real-time feedback mechanism provides ongoing detection without requiring manual inspection, significantly reducing inspection time while maintaining high detection accuracy.
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 efficient detection of battery cell swelling without additional devices, reducing production costs and allowing for broader application across various battery types and cooling systems, while maintaining battery system performance and safety.
Implementation Method 1
first and second temperature measurement units disposed in the battery module to measure a temperature of the battery module at regular intervals
Implementation Method 2
a cooling fan for cooling the battery module
Implementation Method 3
a swelling occurrence determination unit for determining whether a swelling of the battery module occurs using the temperature of the battery module measured in the first and second temperature measurement units
Data Source
AI summary
A system and method for detecting swelling of a battery cell using a temperature sensor pre-mounted on a battery module without a separate additional device.