Fused Cover Assembly for Battery Voltage Sensing Protection
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Solution Overview
Problem
Existing battery systems for hybrid and electric vehicles lack short-circuit protection for voltage sensing connections, which are vulnerable to damage and potential short circuits, especially in the event of a collision.
Innovation Solution
A fused cover assembly with fused connections is introduced, featuring a fuse device that opens the circuit when excessive current is detected, providing protection against short circuits while allowing individual cell voltage monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensing lines are routed from battery to controller for voltage monitoring, then cell voltage sensing capability is achieved, but vulnerability to short-circuit damage increases
Solution Approach 1:
A fused cover assembly is introduced as an intermediary component between the battery cells and the external environment. This assembly contains fuse devices that act as mediators to protect the sensing connections by opening the circuit when excessive current is detected, thereby preventing short-circuit damage while maintaining voltage sensing capability
Solution Approach 2:
Fuse devices are pre-installed within the cover assembly before the battery is assembled. These fuses are positioned in advance to protect the sensing lines that will connect to each cell, providing preliminary protection against potential short-circuit conditions before they can cause damage
2Reliability
If fuse devices are added to protect sensing connections, then short-circuit protection is provided, but device complexity increases
Solution Approach 1:
The fuse devices are merged with the cover assembly, combining the protective function with the existing structural component. By integrating the fuses into the cover rather than adding separate protection mechanisms, the design provides short-circuit protection while minimizing increases in overall device complexity
Solution Approach 2:
The cover assembly serves multiple functions: it provides structural coverage for the battery cells, houses the fuse devices for protection, and maintains the sensing connections. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device 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
The fused connections effectively prevent short-circuit damage to battery cells, ensuring safe operation and reliable voltage sensing without interfering with the battery's power supply or charging capabilities.
Implementation Method 1
The fuse device is configured to open-circuit the corresponding sense connection when excessive current flows through the fuse device
Data Source
AI summary
A fused cover assembly for a battery system. The fused cover assembly includes an attachment means configured to attach the assembly to a battery formed of a plurality interconnected cells, and a plurality of fused connections configured to make electrical contact with the interconnected cells and thereby provide a sense connection to the cells of the battery that is fused. If the sense connection to the battery cells is short-circuited, a fuse device open-circuits to protect the cell from being damaged.