Remote Battery Fault Detection Using Phase-by-Phase BMS Data
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Solution Overview
Problem
The increasing frequency of unforeseen battery fires in lithium-ion battery storage systems, particularly in electrically powered vehicles, due to inadequate detection of critical faults in battery management systems.
Innovation Solution
A method and system for early detection of critical faults in batteries, involving remote diagnosis through a battery management system (BMS) that compares battery data with reference data on a phase-by-phase and cycle-by-cycle basis, using electrical characteristics such as current, voltage, and temperature, to identify potential faults and prevent fires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery management systems monitor electrical characteristics cyclically and periodically, then measurement coverage is achieved, but detection speed and early fault identification are insufficient
Solution Approach 1:
The system performs preliminary actions by continuously monitoring electrical characteristics (current, voltage, temperature) and comparing them against reference data during normal operation. This allows the system to detect deviations indicating critical faults before they escalate into battery fires, enabling preventive rather than reactive safety measures.
Solution Approach 2:
The system implements feedback by comparing measured electrical characteristics with reference data and using this comparison to identify critical faults. The continuous loop of measurement, comparison, and fault identification enables real-time detection and response to developing battery issues.
2Loss of information
If sensor control units communicate measured values cyclically to main control unit, then data collection is achieved, but remote diagnosis capability is insufficient
Solution Approach 1:
The system introduces an intermediary diagnostic layer that receives electrical characteristic data from sensor control units and performs comparative analysis against reference data. This intermediary layer enables remote diagnosis capabilities without requiring direct access to battery internals, maintaining system modularity while enhancing diagnostic functionality.
3Measurement precision
If battery management systems monitor individual battery cells, then measurement precision is improved, but ability to detect critical faults leading to fires remains insufficient
Solution Approach 1:
The system segments the monitoring approach by analyzing electrical characteristics (current, voltage, temperature) of individual battery cells and comparing them against reference data for each cell. This segmented approach enables precise measurement while the comparative analysis across multiple cells identifies patterns indicating critical faults that could lead to fires.
Solution Approach 2:
The system replaces physical inspection and mechanical monitoring approaches with electrical and computational methods. By using electrical characteristic measurements and digital comparison algorithms, the system achieves both measurement precision and fire prevention capability without requiring physical intervention or complex mechanical diagnostic systems.
Data Source
AI summary
A method for early detection of critical faults of a battery (4, 5, 6), after commissioning and during battery operation of the battery (4, 5, 6), comprises receiving battery data provided by a battery management system, BMS (2), associated with the battery (4, 5, 6), at a remote diagnostic unit (3), the battery data relating in time to electrical characteristics of the battery (4, 5, 6) measured during battery operation; and performing a remote diagnosis of the battery (4, 5, 6) by comparing the received battery data with reference battery data phase by phase and/or cycle by cycle, wherein a phase is one of: a charging phase, a transition phase and a discharging phase in relation to the battery operation, and wherein a cycle comprises successive phases of the charging phase, the transition phase and the discharging phase.