Multi-Layer Battery Undershield Sensing for Impact Damage Assessment
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Solution Overview
Problem
Existing battery arrangements in electric vehicles lack effective detection of the extent of damage to the protective plate and the battery, leading to potential false alarms and unnecessary shutdowns.
Innovation Solution
A multi-layer protective plate with embedded deformation sensors at each layer, allowing for quantification of impact severity and estimation of battery stress, along with a cooling plate for additional damage detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single deformation sensor is used on the protective plate, then damage detection is enabled, but the extent of damage cannot be reliably assessed leading to false alarms and unnecessary shutdowns
Solution Approach 1:
The protective plate is divided into multiple layers (first protective layer and second protective layer), with separate deformation sensors (first deformation sensor and second deformation sensor) installed on each layer. This segmentation allows independent measurement of deformation at different depths, enabling precise assessment of impact severity and distinction between minor surface damage and critical battery-threatening damage.
2Reliability
If the battery is switched off immediately upon detecting protective plate damage, then safety is ensured, but vehicle availability decreases due to unnecessary shutdowns for minor damage
Solution Approach 1:
Different response strategies are applied based on the localized deformation measurements from different layers. Minor deformation detected only in the second layer triggers a warning without shutdown, while deformation in both layers or exceeding threshold values triggers safety shutdown. This localized quality assessment enables differentiated safety responses that maintain vehicle availability for minor incidents while ensuring safety for critical damage.
Solution Approach 2:
The deformation sensors provide continuous feedback on the state of the protective plate and its layers. This feedback is evaluated by the control unit to determine the appropriate response (warning vs. shutdown). The multi-layer feedback mechanism enables nuanced decision-making that balances safety requirements with vehicle availability, avoiding unnecessary shutdowns for minor damage.
3Measurement precision
If a multi-layer protective plate with multiple deformation sensors is used, then damage extent can be reliably assessed, but device complexity increases
Solution Approach 1:
The protective plate structure uses a nested arrangement where the first protective layer and second protective layer are stacked one on top of the other, with deformation sensors embedded within each layer. This nested structure achieves sophisticated multi-point measurement capability while maintaining a compact, integrated design that does not significantly increase overall complexity compared to a single-layer approach.
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 assessment of damage extent to both the protective plate and battery, reducing unnecessary shutdowns and increasing vehicle availability by allowing continued use with minor damage.
Implementation Method 1
the deformation sensor comprises an electrically conductive coating that is applied to the protective plate, while an evaluation circuit detects a change in the resistance of the deformation sensor
Implementation Method 2
a flow of coolant through the cooling plate is monitored, for example by a pressure sensor
Data Source
AI summary
A battery arrangement for an electric vehicle including a battery housing and a plurality of battery cells. The battery cells are arranged in the battery housing. A protective plate is arranged on a side of the battery and faces toward a roadway. A deformation detection device includes at least one deformation sensor arranged at the protective plate. The protective plate is constructed of multiple layers and includes at least one first layer and one second layer separate from the first layer. The deformation detection device includes a first deformation sensor and a second deformation sensor. The first deformation sensor is arranged at the first layer of the multi-layer protective plate and the second deformation sensor is arranged at the second layer of the multi-layer protective plate.