External Battery Connector for Individual Cell Balancing
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Solution Overview
Problem
Conventional methods for balancing voltage in battery modules are cumbersome, requiring disassembly of the battery, potential damage from opening, and inefficient charging/discharging due to low current sampling wires.
Innovation Solution
A device comprising an external connector with external terminals connected to junction terminals via wires, allowing for independent charging of cell blocks without disassembling the battery, thereby facilitating balance charging and discharging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the battery is removed from the vehicle to charge and discharge abnormal cells, then the cells can be accessed for charging/discharging, but the battery is very heavy and hard to remove
Solution Approach 1:
The battery system is segmented into modular components with independent access points. The external connector provides separate access to individual cell blocks, allowing targeted charging/discharging operations without moving the entire battery assembly.
2Ease of operation
If the battery is opened to access cell terminals, then the cells can be charged/discharged, but the waterproof protection of the battery is damaged
Solution Approach 1:
The external connector is extracted as a separate access mechanism from the battery housing. It provides a dedicated waterproof interface that eliminates the need to open the battery casing, thereby preserving the integrity of the waterproof seal while enabling cell access.
3Ease of operation
If sampling wires of BMS are used to charge/dischARGE abnormal cells, then the cells can be accessed, but the current is low and charging/discharging time is very long
Solution Approach 1:
The external connector serves as an intermediary device between the charger and the cell blocks. It provides dedicated high-current pathways through separate terminal connections, bypassing the current limitations of BMS sampling wires and enabling faster charging/discharging operations.
4Ease of operation
If conventional methods are used to charge/dischARGE abnormal cells, then the process can be performed, but it is a hard task and takes a long time
Solution Approach 1:
The external connector is pre-configured with dedicated terminal connections for each cell block, establishing ready-to-use high-current pathways before charging/discharging operations begin. This preliminary setup eliminates the need for complex connection procedures during actual operations.
5Device complexity
If cells are charged/discharged through the same process, then the process is simple, but abnormal cells have different status and remain different after charging/discharging
Solution Approach 1:
The external connector enables independent local control of charging/discharging parameters for each cell block. Different current levels, voltages, and timing can be applied to individual cells based on their specific conditions, allowing customized balancing operations that address each cell's unique status.
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 easy and efficient balance charging and discharging of cell blocks, extending battery life by ensuring all cell blocks reach a uniform condition, reducing the need for frequent battery module operations.
Implementation Method 1
The external terminals of the external connector are electrically connected to the cell blocks through the external wires, the junction terminals of the junction terminal block and the junction wires respectively
Data Source
AI summary
A battery includes a case, in which a battery module, a battery management system and a junction terminal block are received. The battery module has cell blocks electrically connected in series, and each of the cell blocks has electrodes. The junction terminal block has a plurality of junction terminals to be electrically connected to the electrodes of the cell blocks through a plurality of junction wires respectively. The battery further has an external connector having a plurality of external terminals to be electrically connected to the junction terminals of the junction terminal block through a plurality of external wires. The external terminals of the external connector are electrically connected to the cell blocks through the external wires, the junction terminals of the junction terminal block and the junction wires respectively, so that all the cell blocks are able to be charged individually through the external connector.