Overcharge Protection Device with Diagnostic Voltage Monitoring

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Solution Overview

Problem

Conventional mechanical overcharge protection devices lack a diagnostic function, making it difficult to determine their operational state and failure, which can lead to failure in detecting overcharged battery swelling, potentially causing explosions or ignitions.

Innovation Solution

Incorporating a diagnostic function that detects the voltage between the ends of the mechanical overcharge protection device, using Runaway Arresting Device (RAD) switches to determine if the device is operating normally or has failed, and controlling the main relay switch based on voltage readings to ensure safe disconnection from the charging power source.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanical overcharge protection device is used to detect battery swelling, then overcharge protection function is provided, but the device cannot determine its own operational state or detect failures

Engineering Contradiction:

Improveovercharge protection reliabilityVSAvoiddevice operational state information

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The patent implements a feedback mechanism by connecting a diagnostic circuit that continuously monitors the contact points of the mechanical overcharge protection device. The control unit receives feedback signals indicating whether the contact points are normally connected or open, enabling the system to determine the operational state of the protection device and trigger appropriate error messages or protective actions.

Inventive Principle:

Principle #23Feedback

2Device complexity

If conventional mechanical overcharge protection devices are used, then simple structure is maintained, but the devices cannot detect contact wear or failure due to vibration

Engineering Contradiction:

Improveprotection device structureVSAvoidcontact point reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces pure mechanical detection with an electrical diagnostic system. Instead of relying solely on mechanical indicators, the invention uses electrical circuits to monitor the contact points of the mechanical device, substituting mechanical assessment with electrical sensing to detect contact wear and failure more reliably.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If no diagnostic function is included in the mechanical overcharge protection device, then device simplicity is maintained, but the device cannot detect abnormal battery swelling

Engineering Contradiction:

Improvedevice structureVSAvoidbattery swelling detection

Core Design Contradiction:

Device complexityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent makes the mechanical overcharge protection device multi-functional by integrating both its original protection function and a new diagnostic function. The device now simultaneously performs battery swelling detection and self-diagnosis of its own operational state, eliminating the need for separate monitoring systems while enhancing overall safety.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables accurate diagnosis of mechanical overcharge protection device failures, ensuring a fail-safe overcharge protection mechanism and improving safety by preventing overcharging-related incidents.

Implementation Method 1

a control unit for diagnosing whether the mechanical overcharge protection device is operating or has failed by detecting a voltage between two ends of the mechanical overcharge protection device

Methodology Applied

Scientific EffectVoltage detection: Electric Field

Implementation Method 2

a mechanical overcharge protection device, connected between a relay actuation coil of a main relay and a ground, for interrupting a connection between the relay actuation coil and the ground when a degree of swelling of a battery is equal to or greater than a predetermined value

Methodology Applied

Scientific EffectMechanical switching: Mechanical Force

Data Source

PatentUS10651662B2Overcharge protection device and method including diagnostic function

Publication Date: 2020.05.12 SK ON CO LTD

AI summary

Disclosed herein is an overcharge protection device including a diagnostic function. The overcharge protection device comprises: a mechanical overcharge protection device, connected between the relay actuation coil of a main relay and a ground, for disconnecting the connection between the relay actuation coil and the ground when the degree of swelling of a battery is equal to or greater than a predetermined value; and a control unit for diagnosing whether the mechanical overcharge protection device is operating or has failed by detecting the voltage between the two ends of the mechanical overcharge protection device. Accordingly, because whether the mechanical overcharge protection device is operating or has failed may be diagnosed accurately, it is possible to detect in advance that the mechanical overcharge protection device may not be operating normally due to the defects or failure thereof whereby a fail-safe overcharge protection device may be embodied and safety may be improved.