Dual-Voltage Battery Block Current Sensor Calibration
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Solution Overview
Problem
Conventional dual-voltage batteries lack the ability to monitor and manage currents through individual battery cell blocks separately, which hinders reliable operation and safety of electrical consumers in vehicles.
Innovation Solution
The dual-voltage battery incorporates block current sensors with measuring resistors and a total battery current sensor, allowing for separate monitoring of block currents and providing redundant measurement capabilities, with the total battery current sensor ensuring high accuracy and calibrating less precise block current sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If block current sensors are provided for each battery cell block to monitor individual currents, then the monitoring reliability and safety of the dual-voltage battery is improved, but the device complexity and cost increase due to multiple sensors and measuring resistors
Solution Approach 1:
The battery system is divided into multiple battery cell blocks, each equipped with its own block current sensor and measuring resistor. This segmentation allows independent monitoring of current in each block, enabling detailed tracking of functional status, load, and state of charge for each block, thereby improving overall monitoring reliability without requiring a single complex centralized sensor system
Solution Approach 2:
Measuring resistors are introduced as intermediary components in series with each battery cell block to enable current measurement. These resistors convert electrical current into measurable voltage signals that can be processed by the control unit, facilitating reliable current monitoring while maintaining electrical isolation and safety in the high-voltage system
2Measurement precision
If high-precision current sensors are used for all battery cell blocks, then the measurement accuracy is improved, but the cost of the dual-voltage battery increases significantly
Solution Approach 1:
Different measurement accuracy requirements are applied to different parts of the system. The total battery current sensor (first current sensor) is designed with high measurement precision for accurate overall current monitoring and calibration functions. In contrast, the block current sensors (second current sensors) can use lower-precision, more cost-effective sensors since their primary function is relative monitoring and state tracking rather than absolute precision measurement
Solution Approach 2:
The control unit performs calibration by comparing measurements from the total battery current sensor with the sum of measurements from individual block current sensors. This feedback mechanism allows the system to detect and compensate for measurement deviations in the block current sensors, maintaining acceptable measurement accuracy while using lower-cost sensors for individual blocks
3Reliability
If multiple current sensors are installed in the dual-voltage battery, then redundant measurement capability and safety are improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The control unit is designed to integrate multiple measurement functions into a single component. It simultaneously processes signals from the total battery current sensor, individual block current sensors, and cell voltage sensors, performing calibration, state estimation, and safety monitoring functions. This merging of functions into a centralized control unit simplifies the overall system architecture and reduces assembly complexity compared to having separate dedicated circuits for each function
Solution Approach 2:
The control unit serves multiple purposes: it monitors cell voltages, processes current measurements from multiple sensors, performs calibration routines, determines state of charge, and implements safety logic. This multi-functional design consolidates what would otherwise require multiple separate components, reducing the overall number of parts and simplifying manufacturing and assembly processes
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 setup enables detailed monitoring of battery cell block status, load, and state of charge, ensuring reliable operation and safe electrical supply by detecting critical states and improving the accuracy of block current sensors through calibration.
Implementation Method 1
which is designed for measuring a block current through the one associated battery cell block
Data Source
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AI summary
The invention relates to a dual-voltage battery for a vehicle, comprising a plurality of battery cells, wherein in each case a group of battery cells is connected to form a battery cell block, and comprising a battery electronics with a plurality of power switching elements for serial and/or parallel connection of in any case individual battery cell blocks, wherein, in a first connection arrangement of the battery cell blocks, a first voltage, and in a second connection arrangement of the battery cell blocks, a second voltage is provided, characterized in that a block current sensor having a measuring resistor is assigned to at least individual battery cell blocks, said block current sensor being designed to measure a block current flowing through the assigned one battery cell block.