Busbar Link Sensor Layout for Cell Current Balancing
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Solution Overview
Problem
Current battery monitoring systems in electric vehicles cannot accurately determine individual current flows in battery cells, limiting real-time monitoring and diagnosis, and are not easily retrofittable to existing busbar and battery modules.
Innovation Solution
A sensor arrangement comprising a network of magnetic field sensors and a processor that determines current flows in busbar links, allowing for non-invasive monitoring of current in each cell within a battery module, enabling real-time data collection and integration into existing battery systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single sensor is used inside the battery pack to measure magnetic field, then the device complexity is reduced, but the measurement precision of individual cell current is insufficient
Solution Approach 1:
The patent divides the monitoring system into multiple segments by placing individual sensors at each busbar link location. This segmentation allows each sensor to independently measure current in its specific busbar link, providing precise individual cell current measurement while maintaining manageable system complexity through modular sensor placement.
2Ease of manufacture
If sensors are integrated into the busbar during fabrication, then the ease of manufacture is improved, but the adaptability to existing systems is reduced
Solution Approach 1:
The patent provides a dynamic solution that adapts to different manufacturing scenarios. The sensor arrangement can be integrated during busbar fabrication for new systems, or retrofitted to existing busbars through clamping or mounting mechanisms. This dynamic approach allows the same sensor technology to serve both manufacturing efficiency and system adaptability needs.
3Reliability
If a non-invasive sensor arrangement is used on the exterior of the busbar, then the reliability of current measurement is improved, but the device complexity increases
Solution Approach 1:
The patent uses magnetic field sensing as an intermediary method to measure current without direct electrical contact with the busbar. Magnetic sensors detect the magnetic field generated by current flow in the busbar, providing reliable current measurement while electrically isolating the sensing system from the high-current busbar, thus improving reliability without requiring complex electrical connections.
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
This solution provides accurate, real-time monitoring of current flows and cell conditions, facilitating early detection of faults, improved battery health estimation, and enhanced safety by preventing overheating, while being cost-effective and adaptable to existing systems.
Implementation Method 1
When current flows through a conductor (such as a busbar), an electromagnetic field is generated which can be detected by magnetic sensors and used to determine the current flow
Data Source
AI summary
A sensor arrangement for a network of busbar links of a battery module is provided, the sensor arrangement comprising: an array of sensors, each sensor having an output arranged to provide an indication of current in a respective busbar link of the network; a processor coupled to the outputs of the sensors and configured to: receive data from the sensor outputs; process the data to determine a current in each of a set of busbar links that are connected at a node of the network; and compare the currents in the busbar links of the set to determine an overall current at the node.