Battery Management System Insulation Segmentation
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Solution Overview
Problem
Current battery management systems for high-voltage batteries face challenges in implementing sufficient insulation, particularly when connected to utility grids with transient high voltages, as commercially available insulating devices often have insufficient terminal spacing, leading to increased system costs for achieving required insulation distances.
Innovation Solution
A battery management system design that incorporates a voltage measuring unit, controller, interface connecting unit, and a circuit board with distinct regions, utilizing two insulating devices to maintain insulation distances of 7 mm each, effectively achieving the necessary 14 mm air clearance for reinforced insulation without the need for expensive long-terminal insulating devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single insulating device with long terminal spacing is used to achieve reinforced insulation of 14 mm, then insulation protection is ensured, but system cost increases significantly
Solution Approach 1:
The patent divides the single 14 mm insulation requirement into two separate 7 mm insulation stages using two ordinary insulating devices. The first insulating device provides 7 mm insulation between primary and intermediate circuits, and the second insulating device provides another 7 mm insulation between intermediate and secondary circuits, achieving cumulative reinforced insulation protection while using readily available, cost-effective components.
Solution Approach 2:
The patent introduces an intermediate circuit as a mediator between the primary and secondary circuits. This intermediate circuit serves as a buffer zone that allows two ordinary insulating devices to be chained together, each providing 7 mm insulation, to collectively achieve the required 14 mm reinforced insulation protection without requiring expensive specialized components.
2Length of stationary object
If the air clearance between conductive patterns is increased to meet insulation requirements, then insulation distance is improved, but the space between terminals of insulating devices must be increased
Solution Approach 1:
The patent segments the total 14 mm insulation distance into two separate 7 mm stages, each handled by an ordinary insulating device. This segmentation allows the use of standard off-the-shelf components with 7 mm terminal spacing rather than requiring custom-designed insulating devices with 14 mm spacing, thereby reducing volume and cost while maintaining the required total insulation distance.
Data Source
AI summary
A battery management system includes a circuit board having a first region provided with a voltage measuring unit, a second region provided with a controller, a relay region that is disposed at a first insulation distance from the first region and at a second insulation distance from the second region, and a third region provided with an interface connecting unit. The third region is disposed at a third insulation distance from the second region. The third insulation distance is shorter than each of the first and the second insulation distances. The battery management system further includes a first insulating device connecting between the first region and the relay region, a second insulating device connecting between the relay region and the second region, and a third insulating device connecting between the second region and the third region.