Integrated Data Acquisition Device for Battery Fault Detection
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Solution Overview
Problem
Current battery monitoring systems in electric vehicles face challenges in detecting faults within the monitoring devices themselves, leading to potential dangerous conditions due to the lack of redundancy, increased cost, and system complexity, as well as the inability to determine the type and severity of faults.
Innovation Solution
An integrated standard-compliant data acquisition device with a multiplexer, analog-to-digital converter, and communication circuitry is used to detect and rank faults by comparing circuit values under different conditions, allowing for internal fault detection and cell balancing, reducing the need for multiple redundant devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery monitoring systems are used without internal fault detection capability, then the system is simpler and less expensive, but the safety is compromised due to inability to detect faults within the monitoring device itself
Solution Approach 1:
The patent merges the fault detection functionality into the existing monitoring device by adding an internal analog-to-digital converter and control logic that can self-diagnose. This combines the monitoring and self-detection functions into a single integrated device rather than requiring separate redundant monitoring devices, thus improving safety while avoiding excessive system complexity
Solution Approach 2:
The monitoring device performs self-diagnostics by using its own internal resources (ADC, control logic, multiplexers) to detect faults within itself. The device monitors its own circuit values under different conditions and compares them to identify internal failures, enabling the system to serve its own safety needs without external intervention or additional redundant devices
2Reliability
If multiple redundant monitoring devices are deployed to detect internal faults, then the reliability improves, but the cost and system complexity increase
Solution Approach 1:
Instead of using multiple separate monitoring devices to achieve fault detection, the patent combines all monitoring and self-detection functions into a single integrated device. The device uses internal multiplexers to switch between different measurement paths and an internal ADC to perform conversions, eliminating the need for redundant external devices while maintaining comprehensive fault detection capability
Solution Approach 2:
The single monitoring device is designed with multi-functionality, serving both as the primary battery monitor and as its own self-diagnostics system. The control logic can configure the multiplexers and ADC to perform different functions including normal monitoring and internal fault detection, allowing one device to replace what would traditionally require multiple specialized devices
3Ease of manufacture
If a single monitoring device is used without internal fault detection, then the cost is reduced, but the ability to determine fault type and severity is lost
Solution Approach 1:
The monitoring device uses its own internal ADC and control logic to perform self-diagnostics, comparing circuit values measured under different conditions to identify internal faults. This self-service approach enables comprehensive fault diagnosis capability within a single device without requiring additional expensive diagnostic equipment or redundant monitoring systems
Solution Approach 2:
The device detects faults by measuring circuit values under different operational conditions and comparing the results. The control logic changes parameters such as multiplexer configurations and measurement conditions to gather different data sets, enabling the system to determine both the presence and type/severity of faults using the same single device
Data Source
AI summary
An integrated standard-compliant data acquisition device includes an electrically insulating package including a plurality of conductive leads and an integrated circuit (IC) disposed within the electrically insulating package and electrically coupled to at least some of the plurality of conductive leads. The IC includes a first multiplexer (MUX), a second MUX, a third MUX, an analog-to-digital converter (ADC), a plurality of registers, a fourth MUX, control logic, and communication circuitry. In operation, a first circuit value under a first condition can be determined and stored, a second circuit value under a second condition can be determined and stored, and the decision as to whether there is a fault condition can be mad by comparing the first circuit value and the second circuit value.