Lead-Based Temperature Monitoring for Battery Connector Heat
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Solution Overview
Problem
Existing methods for monitoring the temperature of electrical/electronic components in energy storage systems often result in unnecessary reduction of current or power, leading to inefficiencies in charging, recuperation, and vehicle performance.
Innovation Solution
A method using a temperature sensor in heat-conductive contact with the electrical lead system to estimate the temperature of electrical/electronic components, accounting for heat conduction delays, allowing for more precise and efficient monitoring and reducing power adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature sensors are installed in multiple components to be monitored, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the temperature monitoring function for multiple components into a single temperature sensor that measures the temperature of the electrical lead system. By placing one temperature sensor in the electrical lead system that conducts heat from multiple connectors, the system achieves centralized temperature monitoring without requiring individual sensors at each component location, thus reducing device complexity while maintaining measurement capability.
Solution Approach 2:
The electrical lead system acts as an intermediary that conducts heat from multiple connectors to a single temperature sensor. The heat conduction path through the electrical leads allows the temperature sensor to indirectly measure temperatures at distant connector locations without direct contact, serving as a thermal mediator that bridges the gap between multiple heat sources and a single measurement point.
2Reliability
If worst-case scenario is taken into account for safe operation, then reliability is improved, but productivity deteriorates
Solution Approach 1:
The patent implements feedback by continuously monitoring the actual temperature of the electrical lead system and using this real-time data to adjust current limits dynamically. Instead of relying on static worst-case assumptions, the system measures actual temperature conditions and adjusts operating parameters accordingly, allowing the system to maintain reliability while avoiding unnecessary conservative restrictions on charging and discharge operations.
Solution Approach 2:
The system changes the operating parameters (current limits, power levels) based on actual measured temperature conditions rather than fixed worst-case values. When temperatures are within safe ranges, the system allows higher current and power levels to maximize productivity. When temperatures approach critical thresholds, the system dynamically reduces current limits, thus optimizing the balance between reliability and productivity based on real-time conditions.
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 approach enables more accurate temperature monitoring of electrical/electronic components, reducing unnecessary power reductions and optimizing energy use in energy storage systems, particularly during charging and vehicle operation.
Implementation Method 1
a temperature sensor in heat-conductive contact with the electrical lead system. The electrical lead system also conducts the heat, which for example arises in the region of the contacts of a connector, over a particular distance up to the temperature sensor
Data Source
AI summary
A method for monitoring a temperature of an electrical/electronic component connected via an electrical lead system includes using a temperature sensor in heat-conductive contact with the electrical lead system to record a current temperature and determining a temperature of the electrical/electronic component by a model from the current temperature of the temperature sensor when a current is switched off.