Battery Voltage Detection Circuit Board Mounting
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Solution Overview
Problem
The existing voltage detection systems for battery packs in hybrid vehicles require labor-intensive harness layout and are prone to short circuits during crashes, which can lead to fires and smoke emissions.
Innovation Solution
Mounting circuit boards with voltage detection circuits directly on battery packs, enabling sequential information transmission between control circuits, reducing the number of harnesses and distances, and using daisy chain communication to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If detection wire harnesses are laid out from cell batteries to circuit board, then voltage detection is achieved, but labor hours increase and workability deteriorates
Solution Approach 1:
The battery pack is divided into multiple modules, each with its own circuit board mounted directly on the module. This segmentation eliminates the need for long harnesses connecting individual cells to a centralized board, reducing assembly labor while maintaining detection reliability.
Solution Approach 2:
The circuit board is merged with the battery module structure by mounting it directly on the module housing. This integration eliminates separate harness connections and reduces the number of assembly steps, improving productivity without compromising voltage detection capability.
2Reliability
If detection wire harnesses are laid out from cell batteries to circuit board, then voltage detection is achieved, but harness disconnection during crash causes short circuit and fire risk
Solution Approach 1:
The vulnerable wire harnesses are extracted from the system by eliminating them entirely. Voltage detection is achieved through direct electrical connections integrated into the circuit board mounting structure, removing the source of crash-induced short circuits and fire risk.
Solution Approach 2:
The circuit board is pre-mounted on the battery module with integrated connection points before assembly is completed. This preliminary integration ensures that no separate harnesses need to be connected later, eliminating the risk of harness disconnection during crashes.
3Productivity
If circuit boards are mounted on battery packs with sequential information transmission, then number of harnesses is reduced, but communication complexity increases
Solution Approach 1:
The communication system uses dynamic sequential transmission where each circuit board transmits information to the next in the sequence. This dynamic approach simplifies the overall system architecture compared to requiring all boards to communicate simultaneously with a central controller, reducing communication complexity while maintaining assembly productivity.
Data Source
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AI summary
A voltage detection apparatus includes first to third circuit boards which are provided on first to third battery packs of a battery system respectively. The first circuit board includes a first voltage detection portion which detects a voltage of the first battery pack, a control portion which controls the first voltage detection portion, and a first insulation device which connects the first voltage detection portion with the control portion. The second circuit board includes a second voltage detection portion which detects a voltage of the second battery pack, and a second insulation device which connects the second voltage detection portion with the control portion. The third circuit board includes a third voltage detection portion connected in series with the second voltage detection portion and which detects a voltage of the third battery pack. The control portion controls the second and third voltage detection portions.