Bus Bar Integrated Voltage and Temperature Sensing Apparatus
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery systems for electric vehicles face challenges in monitoring voltage and temperature parameters across multiple cells, which affects battery lifespan and performance, and current sensor placement complicates manufacturing and increases costs.
Innovation Solution
A sensing apparatus comprising an elongated substrate and multiple sensors, each contacting a respective cell, is integrated along one side of the battery cell group, separate from the bus bar, allowing for efficient monitoring of voltage and temperature without interfering with bus bar welding, thereby improving manufacturing efficiency and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are integrated into the battery system to monitor voltage and temperature, then battery management and lifespan are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The sensing apparatus is merged with the bus bar structure, where the bus bar serves dual functions as both an electrical connector and a mounting substrate for the sensors. This integration eliminates the need for separate sensor mounting structures, thereby improving battery management while reducing manufacturing complexity.
Solution Approach 2:
The bus bar is designed to perform multiple functions: electrical connection between cells and as a structural platform for sensor placement. This multi-functionality reduces the overall component count and simplifies the manufacturing process while maintaining reliable voltage and temperature monitoring.
2Measurement precision
If sensors are placed to contact each cell for monitoring, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The sensing apparatus is divided into multiple discrete sensor units, each corresponding to a specific cell. This segmentation allows each sensor to independently monitor its designated cell with high precision while keeping the overall system modular and manageable during assembly.
Solution Approach 2:
Sensors are arranged in a linear array along the length of the bus bar, utilizing the longitudinal dimension of the battery assembly. This spatial arrangement allows each sensor to contact its respective cell along the length of the battery pack, achieving precise monitoring without increasing vertical or horizontal complexity.
3Reliability
If bus bar welding is performed first, then electrical connection reliability is improved, but sensor integration becomes more difficult
Solution Approach 1:
The sensing apparatus is pre-integrated onto the bus bar structure before the welding process. This preliminary action allows sensors to be positioned and secured on the bus bar surface prior to welding, ensuring that the welding process does not displace or damage the sensors while maintaining electrical connection reliability.
Data Source
AI summary
The embodiments described herein include a system and a method. One embodiment provides a sensing apparatus for a battery system having a plurality of cells. The sensing apparatus includes an elongated substrate configured to extend along one side of the plurality of cells and a plurality of sensors, each corresponding to a respective one of the plurality of cells, and each configured to contact its respective cell.