Deformation Sensing Pin Joint Amplifier for EV Battery Safety
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Solution Overview
Problem
Current methods fail to accurately and reliably detect deformations on surfaces, such as those on electric vehicle bottom covers, which can lead to hazardous conditions like thermal runaway and damage to battery systems, as these deformations may go unnoticed until significant damage occurs.
Innovation Solution
A sensing device comprising a support unit with a first and second frame mechanically coupled at a pin joint, amplifying relative movement, and a sensor (resistive, capacitive, inductive, or piezoelectric strain gauge) to detect deformations by varying electrical properties, triggering an alarm when deviations from normal ranges are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is directly coupled to the surface, then the device complexity is reduced, but the measurement precision is insufficient to detect small deformations
Solution Approach 1:
A support unit with first and second frames is introduced as an intermediary between the surface and the sensor. The first frame couples to the surface at a first location, the second frame couples to the surface at a second location, and these frames are mechanically coupled together. This intermediary mechanical structure amplifies the relative movement between the two surface locations, enabling the sensor to detect deformations with higher precision while maintaining reasonable device complexity.
2Reliability
If the sensor measures small relative movements directly on the surface, then the device complexity is minimized, but the reliability of deformation detection is insufficient
Solution Approach 1:
The support unit with first and second frames acts as a mechanical amplifier and intermediary structure. By coupling the first frame to the surface at a first location and the second frame to the surface at a second location, and mechanically coupling these frames together, the system amplifies small relative movements caused by surface deformations. This makes the deformations reliably detectable by the sensor while maintaining a relatively simple overall device structure.
3Difficulty of detecting and measuring
If no amplification mechanism is used, then the device complexity is low, but the difficulty of detecting and measuring deformations increases
Solution Approach 1:
The support unit with first and second frames serves as a mechanical amplifier that reduces the difficulty of detecting deformations. The first frame couples to the surface at a first location, the second frame couples to the surface at a second location, and their mechanical coupling amplifies the relative movement between these locations. This amplification makes small deformations easier to detect and measure by the sensor.
Solution Approach 2:
The invention transforms the detection problem by introducing a mechanical amplification dimension. Instead of directly measuring small linear displacements on the surface, the support unit with first and second frames converts these small displacements into larger relative movements through mechanical coupling, effectively changing the measurement scale and reducing detection difficulty.
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 solution provides early and accurate detection of deformations, preventing potential hazards by alerting authorities before significant damage occurs, ensuring the safety of the vehicle and its occupants.
Implementation Method 1
a pin joint configured to mechanically couple the first frame to the second frame, such that a first relative movement between the first end of the first frame and the first end of the second frame is amplified to a second relative movement between a second end of the first frame and a second end of the second frame
Implementation Method 2
the sensor comprises a resistive strain gauge wherein a resistance varies due to the second relative movement and wherein the deformation is detected when the resistance is outside a normal resistance range
Implementation Method 3
the sensor comprises a capacitive strain gauge wherein a capacitance of the strain gauge sensor varies due to the second relative movement and wherein the deformation is detected when the capacitance is outside a normal capacitance range
Implementation Method 4
the sensor comprises an inductive strain gauge wherein an inductance of the strain gauge sensor varies due to the second relative movement and wherein the deformation is detected when the inductance is outside a normal inductance range
Implementation Method 5
the sensor comprises a piezoelectric material, wherein the piezoelectric material generates a voltage due to the second relative movement and wherein the deformation is detected when the voltage is outside a normal voltage range
Data Source
AI summary
Methods, apparatuses and systems for a sensing deformation in a surface are disclosed herein. An example device may include a support unit including a first frame and a second frame. A first end of the first frame and a first end of the second frame are mechanically coupled to the surface. The sensing device includes a pin joint that mechanically couples the first frame to the second frame, such that a first relative movement between the first end of the first frame and the first end of the second frame is amplified to a second relative movement between a second end of the first frame and a second end of the second frame. The sensing device includes a sensor that senses the second relative movement between the second end of the first frame and the second end of the second frame.