Interwoven Battery Voltage Harness Outside the Load Path
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Solution Overview
Problem
Integrating a voltage sensing harness into a battery system of an electric vehicle is challenging due to mechanical and electrical loads, which can damage the harness and increase the system's height, compromising its durability and performance.
Innovation Solution
An interwoven voltage sense harness is designed to extend along the sides of battery cells, using a flexible circuit insulated by materials like polyvinyl chloride or polyimide film, with exposed traces to measure cell voltage, bonded via laser weld or solder, and featuring varying stiffness portions to accommodate different cell geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the voltage sensing harness is placed on the direct load path to support mechanical loads, then the harness can provide structural support, but the durability and performance of the voltage sensing component deteriorates due to excessive force and stress
Solution Approach 1:
The voltage sensing harness is extracted from the direct load path and repositioned to extend along the sides of battery cells. This separation removes the sensing function from the mechanical load path, allowing the harness to perform voltage sensing without being subjected to excessive compressive forces that would compromise its durability and reliability.
Solution Approach 2:
The harness configuration transitions from a vertical arrangement (extending between cells in the load path) to a lateral arrangement (extending along the sides of cells). This dimensional change repositions the harness outside the direct compressive load path while maintaining its voltage sensing functionality through lateral contact with cell terminals.
2Reliability
If the battery system height is increased to accommodate the voltage sensing harness, then the harness can be properly positioned, but the compactness of the battery system deteriorates
Solution Approach 1:
The harness is reconfigured to extend laterally along the sides of battery cells rather than vertically between cells. This dimensional change allows the harness to be properly positioned for voltage sensing while utilizing the lateral space already available in the battery pack, thereby maintaining compact battery system height.
3Reliability
If excessive materials are used to manufacture the voltage sense component to withstand load forces, then the durability improves, but the weight of the electric vehicle increases
Solution Approach 1:
The voltage sensing harness is extracted from the load-bearing function and repositioned to a non-load-critical location along the cell sides. This allows the harness to be constructed from lighter, more flexible materials suitable for voltage sensing, rather than requiring excessive structural materials to withstand mechanical loads, thereby reducing overall vehicle weight.
Solution Approach 2:
The mechanical stress parameters experienced by the harness are reduced by repositioning it outside the direct load path. This parameter change allows the use of lighter materials with lower mechanical strength requirements while maintaining sufficient durability for voltage sensing applications.
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
This design enhances durability, performance, and compactness by reducing compressive forces on the harness, providing efficient voltage measurement while maintaining a compact battery system.
Implementation Method 1
The harness can be formed of an electrically insulating material that encapsulates a flexible circuit
Implementation Method 2
The trace can contact each of the cells to measure voltage of the cells
Implementation Method 3
The harness can be bonded to each of the plurality of cells via an electrical conductor. The harness can be bonded to each of the plurality of cells via at least one of a laser weld or a solder
Implementation Method 4
The harness can be bonded to each of the plurality of cells via at least one of a laser weld or a solder
Data Source
AI summary
An interwoven voltage sense harness of a battery is provided. A battery system can include cells arranged in an array. The battery system can include a harness. The harness can include a circuit electrically insulated by a material. The harness can extend along a side of the cells. The harness can include a trace. The trace can be electrically coupled to the circuit. The trace can contact each of the cells to measure voltage of the cells. At least one aspect is directed to a method. The method can include providing a battery system comprising a plurality of cells arranged in an array and a harness.