Cavity Pressure Sensor for High-Voltage Battery Damage Detection
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Solution Overview
Problem
It is challenging to predict and detect damage to high-voltage batteries in motor vehicles, particularly during collisions or when driving over elevations, as existing systems lack effective early warning mechanisms.
Innovation Solution
A warning system is implemented with sensors positioned around the high-voltage battery, including a pressure sensor and evaluation device, which detects pressure changes caused by external forces on the underride protection device, triggering a warning signal if the pressure change exceeds a predetermined limit, indicating potential damage to the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are positioned in the surroundings of the high-voltage battery to detect damage early, then the reliability of damage detection is improved, but the device complexity increases
Solution Approach 1:
A cavity is introduced as an intermediary space between the underride protection device and the battery housing. This cavity serves as a mediator that transmits mechanical deformation from the underride protection device to the battery housing, enabling indirect detection of battery damage through pressure changes in the cavity without requiring direct contact sensors on the battery itself.
Solution Approach 2:
The patent replaces complex mechanical damage detection systems with a pressure-based detection system. Instead of using multiple mechanical sensors directly on the battery, a single pressure sensor monitors pressure changes in the cavity, which indirectly reflect battery housing deformation and potential battery damage, thereby simplifying the overall detection system.
2Measurement precision
If a pressure sensor is used to detect pressure changes in the cavity, then the measurement precision of external force detection is improved, but the device complexity increases
Solution Approach 1:
The cavity itself serves the dual function of being both the protective space between the underride protection device and battery housing, and simultaneously the sensing medium for detecting external forces. The pressure changes in the cavity automatically indicate deformation events without requiring additional active sensing components within the cavity, allowing the system to self-monitor through its structural design.
3Difficulty of detecting and measuring
If the cavity is designed to change volume when the underride protection device is deformed, then the sensitivity of damage detection is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The system exploits changes in the physical state of the cavity (volume and pressure) as indicators of external force application. By monitoring pressure changes in the cavity rather than directly measuring minute volume changes or deformation dimensions, the system converts difficult-to-measure geometric parameters into easily measurable pressure parameters, reducing manufacturing precision requirements while maintaining detection sensitivity.
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
The system provides early and reliable warnings of potential high-voltage battery damage, ensuring user safety by detecting pressure changes and alerting the driver to visit a workshop for inspection, thus preventing further damage.
Implementation Method 1
The cavity is designed to experience a pressure change in a pressure in the cavity due to the change of the volume
Implementation Method 2
The pressure sensor can be designed, for example, as a piezoresistive, piezoelectric, capacitive, and/or inductive pressure sensor
Implementation Method 3
The pressure sensor can be designed, for example, as a piezoresistive, piezoelectric, capacitive, and/or inductive pressure sensor
Data Source
AI summary
A warning system and a warning method for a motor vehicle having a high-voltage battery. The warning system includes a battery housing having the high-voltage battery, an underride protection device, a spatially closed cavity, at least one pressure sensor, and an evaluation device. The spatially closed cavity is arranged in a vertical direction of the warning system above the underride protection device and below the battery housing and is designed to change a volume of the cavity upon a deformation of the underride protection device under the action of a predetermined external force on the underride protection device. The at least one pressure sensor is designed to detect a pressure change value that describes a change in pressure in the pressure in the cavity.