Integrated Current Measurement Module for EV Battery Systems
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Solution Overview
Problem
Current current measurement methods in motor vehicle power supply systems are inefficient due to the inaccuracy of Hall sensors and the high cost and additional installation effort required for shunts and U-shaped busbars used in anisotropic magnetoresistance (AMR) sensors, complicating malfunction diagnosis and increasing installation complexity.
Innovation Solution
A connection module for motor vehicle electrical energy storage devices that includes a primary current measurement element, such as a shunt, and a contactlessly operating secondary current measurement element, like an anisotropic magnetoresistance (AMR) sensor, which eliminates the need for a U-shaped busbar and integrates the secondary current measurement within the battery connection module, allowing for simpler and more accurate current measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If Hall sensors are used for current measurement, then the measurement can be performed, but the accuracy is relatively low making malfunction diagnosis difficult
Solution Approach 1:
The patent combines the primary current measurement (via shunt) and secondary current measurement (via AMR sensor) into a single integrated connection module. The AMR sensor is built directly into the connection module housing, allowing both measurement functions to coexist in one compact unit, resolving the contradiction by enabling accurate AMR-based measurement without requiring separate complex external arrangements
Solution Approach 2:
The connection module serves multiple functions: it provides primary current measurement via shunt, secondary current measurement via integrated AMR sensor, and houses both measurement elements within a single structural unit. This multi-functionality allows the system to achieve both acceptable measurement capability and high diagnostic accuracy through redundant measurement paths
2Measurement precision
If a shunt is used as secondary amperemeter, then accurate current measurement is achieved, but the cost increases due to requirement of separate analog-digital converter for each shunt
Solution Approach 1:
The patent replaces expensive shunt-based secondary measurement with a more cost-effective AMR sensor that can be integrated directly into the connection module. The AMR sensor provides sufficient measurement accuracy without requiring separate analog-digital converters for each measurement point, thereby reducing overall system complexity and cost while maintaining measurement precision
3Measurement precision
If AMR sensor is used for secondary current measurement, then measurement accuracy is improved, but additional installation effort is required due to need for separate U-shaped busbar
Solution Approach 1:
The patent integrates the AMR sensor directly into the connection module housing, eliminating the need for separate U-shaped busbars. The sensor is positioned within the housing to detect the magnetic field generated by current flow through the existing busbars, combining the measurement function with the existing structural components and significantly reducing installation complexity
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 simplifies the current measurement process, reduces manufacturing costs, and enhances diagnostic accuracy by eliminating the need for separate busbars and additional installation effort, while maintaining measurement accuracy through contactless operation.
Implementation Method 1
a secondary current measurement element, the secondary current measurement element being a contactlessly operating current measurement element
Implementation Method 2
the use of a shunt as a secondary amperemeter is relatively expensive... An additional option for performing a secondary current measurement is to provide an anisotropic magnetoresistance (AMR) sensor
Data Source
AI summary
A connection module for an electrical energy storage device of a motor vehicle includes a first connection element and a second connection element for connecting to the electrical energy storage device and to a traction network. The connection module includes busbars which connect the first connection element and the second connection element to one another. The connection module further includes a primary current measurement element and a secondary current measurement element, wherein the secondary current measurement element operates contactlessly. A power supply system for a motor vehicle is also provided.