Flat Sensor for EV Battery Housing Deformation Detection
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Solution Overview
Problem
Current electric vehicles and hybrid vehicles lack a cost-effective method to detect deformations in high-voltage accumulator housings, leading to potential safety risks and increased development and production costs due to mechanical over-dimensioning, which restricts vehicle configuration and range.
Innovation Solution
A detection device comprising a flat sensor element applied to the high-voltage accumulator components and an evaluation device that analyzes electrical measured quantities to output warning messages upon resistance changes, allowing for early detection of mechanical deformations without significant weight or space increase, using dielectric elastomeric sensors and electrically conductive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the high-voltage accumulator is mechanically designed to be very robust to accommodate safety-critical damage risk, then safety reliability is improved, but vehicle weight increases and production costs increase due to mechanical over-dimensioning
Solution Approach 1:
The patent applies preliminary action by installing sensor elements on the housing surface before any damage can occur. These sensors continuously monitor for deformations and foreign body contacts, enabling early detection and warning before safety-critical damage happens. This allows the housing to be designed with optimal (not excessive) mechanical strength while maintaining safety through active monitoring.
2Reliability
If the high-voltage accumulator is mechanically designed to be very robust to accommodate safety-critical damage risk, then safety reliability is improved, but production costs increase due to mechanical over-dimensioning
Solution Approach 1:
The sensor elements are applied to the housing surface during the manufacturing process before final assembly. This preliminary application of sensing capability allows the housing to be manufactured with optimized mechanical properties rather than excessive robustness, reducing material costs and manufacturing complexity while ensuring safety through active monitoring.
3Reliability
If the high-voltage accumulator is installed in regions of the motor vehicle that are less susceptible to damage, then safety reliability is improved, but vehicle configuration and range are significantly restricted
Solution Approach 1:
By applying sensor elements to the housing surface before installation, the system enables monitoring of deformations regardless of installation location. This allows the high-voltage accumulator to be installed in optimal positions for vehicle configuration and range without compromising safety, as the sensors will detect any foreign body contacts or deformations that occur during operation.
4Measurement precision
If optical examination is used to detect minor damage to the high-voltage accumulator, then measurement precision is improved, but productivity decreases due to manual inspection requirements
Solution Approach 1:
The sensor elements are applied to the housing surface in such a way that they automatically detect and signal deformations and foreign body contacts during normal vehicle operation. This self-monitoring capability eliminates the need for manual optical examinations, providing continuous precise detection without reducing productivity or requiring vehicle downtime for inspections.
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
Enables the detection of potential damage to high-voltage accumulator components, improving safety by initiating user warnings and reducing production costs through reduced mechanical configuration and increased diagnostic reliability, allowing for more efficient vehicle design and extended range.
Implementation Method 1
the sensor element has a substantially flat embodiment and is applied, at least in part, to a component of the high-voltage accumulator; and an evaluation device for analyzing the electrical measured quantity between the sensor element and a second component of the high-voltage accumulator
Data Source
AI summary
A detection device detects a mechanical deformation of a high-voltage accumulator of a motor vehicle, and includes: a sensor element, which senses an electrical measurement variable, wherein the sensor element is substantially flat and is attached at least partially to a first component of the high-voltage accumulator; and an evaluation device for analyzing the electrical measurement variable between the sensor element and a second component of the high-voltage accumulator and for outputting a corresponding warning on the basis of the electrical measurement variable, wherein at least one region of the surface of the second component is electrically conductive.