Battery Testing Device with Integrated Ultrasonic Sensing
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Solution Overview
Problem
Existing battery testing apparatuses lack the capability to non-destructively monitor the internal state of battery cells during charge/discharge tests, relying solely on electric parameters for state estimation.
Innovation Solution
A battery testing apparatus that incorporates an ultrasonic sensing unit to transmit and receive ultrasonic signals through the battery cell, allowing the controller to determine the battery cell's state based on changes in the ultrasonic signal characteristics during charge or discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an existing simple gripper is used to connect the battery cell to the charger/discharger, then the device complexity is reduced and ease of operation is improved, but the measurement precision and reliability of battery state monitoring deteriorates because no additional diagnostic functions are available
Solution Approach 1:
The patent combines the electrical connection function and ultrasonic sensing function into a single integrated gripper structure. The ultrasonic transmitter and receiver are embedded within the gripper components that already contact the battery terminals, allowing simultaneous electrical charging/discharging and ultrasonic-based internal state monitoring without requiring separate diagnostic equipment
Solution Approach 2:
The gripper is designed to perform multiple functions: electrical connection for charge/discharge operations and ultrasonic signal transmission for internal defect detection. This multi-functional design enables the same component to serve both operational and diagnostic purposes, improving measurement precision without proportionally increasing device complexity
2Reliability
If only electric parameters are used for battery state estimation, then the device complexity is minimized, but the reliability and precision of internal defect detection deteriorates
Solution Approach 1:
The patent introduces ultrasonic waves as an intermediary physical phenomenon to probe the internal state of the battery. The ultrasonic transmitter sends waves through the battery cell, and the receiver detects changes in wave propagation characteristics, serving as a non-invasive mediator that reveals internal conditions such as lithium precipitation or electrode defects without direct chemical or physical contact with battery materials
3Measurement precision
If ultrasonic sensing components are added to the connector, then the measurement precision and reliability of battery state determination is improved, but the ease of manufacture and device complexity worsen
Solution Approach 1:
The ultrasonic transmitter and receiver are nested within the existing gripper structure, utilizing the same spatial envelope and mounting points. The sensing components are integrated into the contact elements that already exist in the connector design, allowing ultrasonic functionality to be added without significantly increasing overall device volume or manufacturing complexity
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 precise estimation of the battery cell's state, including lithium precipitation, electrode lead defects, and remaining lifetime, by combining ultrasonic signal analysis with electric parameter data.
Implementation Method 1
an ultrasonic sensing unit configured to output an ultrasonic signal toward the battery cell and sense an ultrasonic signal passing through the battery cell
Data Source
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AI summary
A battery testing apparatus according to an embodiment includes a connector connected to an electrode of a battery cell, a charging/discharging unit configured to charge or discharge the battery cell through the connector, an ultrasonic sensing unit configured to output an ultrasonic signal toward the battery cell and sense an ultrasonic signal passing through the battery cell, and a controller configured to determine a state of the battery cell based on characteristics of the ultrasonic signal passing through the battery cell, during charge or discharge of the battery cell.