Internal Battery Pack Sensing Module for Precise Cell Voltage Monitoring
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Solution Overview
Problem
Existing traction batteries in electrified vehicles lack efficient internal monitoring and communication systems for battery cell voltages, currents, and temperatures, which can lead to suboptimal performance and management of the battery pack.
Innovation Solution
Incorporating a battery pack sensing module (BPSM) internally within the traction battery, connected to multiple printed circuit boards (PCBs) via sense leads, allowing for wireless communication of sensed data to a battery energy control module, enabling real-time monitoring and control of battery cell characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a battery pack sensing module is integrated internally within the battery housing, then monitoring precision and response time are improved, but device complexity increases
Solution Approach 1:
The battery pack sensing module is nested within the battery housing, with the sensing module containing its own PCB and electronic components housed inside the battery's structural framework. This integration allows the sensing system to be embedded within existing battery components, achieving precise monitoring while utilizing the battery's internal space efficiently.
Solution Approach 2:
The primary PCB within the sensing module serves multiple functions: it provides structural support, electrical connection pathways for voltage sensing, and mounting infrastructure for additional sensing components. This multi-functionality reduces the need for separate dedicated structures, thereby managing complexity while maintaining monitoring precision.
2Loss of information
If multiple PCBs are integrated within the battery housing for sensing and communication, then information communication efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple PCB functions are merged into a unified sensing module architecture where the primary PCB integrates voltage sensing, data processing, and communication capabilities. This consolidation reduces the number of separate components that need to be manufactured and assembled, thereby improving ease of manufacture while maintaining efficient information communication.
Solution Approach 2:
The primary PCB acts as an intermediary between the voltage sensing leads from individual battery cells and the external communication interface. It receives raw voltage signals, processes and consolidates the data, then transmits processed information externally, thereby improving communication efficiency while providing a single standardized interface that simplifies manufacturing.
3Measurement precision
If sense leads are extensively connected to each battery cell, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The complex network of individual voltage sensing connections from each battery cell is extracted and consolidated onto a single primary PCB within the sensing module. This PCB provides centralized connection points for all voltage leads, maintaining precise individual cell monitoring capability while reducing the complexity of interconnections by providing a unified interface structure.
Data Source
AI summary
A battery, such as a traction battery for an electrified vehicle (EV), includes a battery sensor, such as a battery pack sensing module (BPSM), arranged internally within a housing of the battery. The battery further includes one or more battery cell arrays arranged within the housing. Each battery cell array including battery cells and a printed circuit board (PCB) electrically connected with voltage sense leads associated with the battery cells. The battery further includes a primary PCB arranged within the housing and electrically connected to the battery cell array PCBs. The battery sensor is electrically connected to the primary PCB to establish an electrical connection with the battery cell array PCBs whereby the battery sensor can sense the voltages of the battery cells.