Control Module Bus Bar Layout for Battery Noise Isolation

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Solution Overview

Problem

The increasing size of battery modules in high-output motor systems poses challenges in suppressing electromagnetic noise interference and maintaining electrical connection reliability due to the close proximity of the charge/discharge circuit unit and output battery ECU, which can lead to vibration and reliability issues in the connection terminal.

Innovation Solution

A control module is designed to be arranged alongside the battery module with a bus bar for electrical connection, a switch for controlling the connection, a current sensor for detecting current, and a control unit that inputs signals to manage the switch, with the connection terminal closer to the control unit than the switch, effectively separating the noise source from the control unit and shortening the connection terminal to prevent vibration and reliability issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the charge/discharge circuit unit and output battery ECU are disposed close to each other to suppress the size of the battery power source device, then the device size is reduced, but the output battery ECU is easily influenced by electromagnetic noise from the relay

Engineering Contradiction:

Improvebattery power source device sizeVSAvoidelectromagnetic noise influence

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

A connection terminal is introduced as an intermediary component between the current sensor and the output battery ECU. This connection terminal includes a connection portion that is disposed closer to the output battery ECU than the switch, thereby mediating the electrical connection while reducing the impact of electromagnetic noise from the relay on the ECU.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If the charge/discharge circuit unit and output battery ECU are disposed separated from each other to reduce electromagnetic noise influence, then the electromagnetic noise influence is reduced, but the connection terminal becomes long and easy to vibrate, deteriorating electrical connection reliability

Engineering Contradiction:

Improveelectromagnetic noise influenceVSAvoidelectrical connection reliability

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The connection terminal serves as an intermediary that optimizes the balance between noise isolation and connection stability. By positioning the connection portion closer to the ECU than the switch, it provides sufficient separation from electromagnetic noise sources while maintaining a short, stable electrical connection that resists vibration and ensures reliable signal transmission.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If the connection terminal is made long to separate the current sensor from the output battery ECU, then the electromagnetic noise influence is reduced, but the connection terminal becomes easy to vibrate and electrical connection reliability deteriorates

Engineering Contradiction:

Improveelectromagnetic noise influenceVSAvoidconnection terminal stability

Core Design Contradiction:

Object-affected harmful factorsVSStability of the object's composition

Solution Approach 1:

The connection terminal is designed as an intermediary component with optimized geometry and positioning. The connection portion is disposed closer to the output battery ECU than the switch, creating an intermediate structure that provides adequate electromagnetic shielding while maintaining structural stability and minimizing vibration susceptibility.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 configuration effectively suppresses electromagnetic noise interference and maintains electrical connection reliability by isolating the noise source and reducing terminal length, thereby preventing vibration and ensuring stable connections between the control unit and the current sensor.

Implementation Method 1

a current sensor by which a current of the bus bar is detected

Methodology Applied

Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Implementation Method 2

a switch by which an electrical connection between the bus bar and the electric load is switched on and off

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS10991989B2Control module connected to battery module

Publication Date: 2021.04.27 DENSO CORP

AI summary

A control module is arranged side by side with a battery module. The control module include a bus bar by which the battery module and an electric load are electrically connected to each other, and a switch by which an electrical connection between the bus bar and the electric load is switched on and off. The control module further includes a current sensor by which a current of the bus bar is detected; a control unit into which an electric signal of the current sensor is inputted, and by which connection switching of the switch is controlled; and a connection terminal by which the current sensor and the control unit are electrically connected to each other. A connection portion between the connection terminal and the current sensor is more closely disposed at a side of the control unit than a connection portion between the bus bar and the switch.