Serviceable Battery Pack With Segmented Cell Modules
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Solution Overview
Problem
Existing battery packs face challenges in efficient management and extended use due to degradation of lithium-ion battery cells over time, leading to reduced charge capacity and increased risk of thermal events, which can cause cascading failures.
Innovation Solution
The battery pack design incorporates a battery management system (BMS) that monitors and regulates the charging and discharging processes, includes a data logger to track useful life indicators, and allows for tiered access and replacement of cell module assemblies (CMAs) to extend the life of the battery cells, with a compartmentalized structure for enhanced serviceability and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If lithium-ion battery cells are used to power equipment, then high energy density and long operating time are achieved, but degradation over time leads to reduced charge capacity and increased thermal risk
Solution Approach 1:
The battery pack is divided into multiple cell module assemblies (CMAs), each containing multiple battery cells arranged in series. This segmentation allows individual CMAs to be monitored, isolated, and replaced independently, containing thermal risks within specific modules rather than affecting the entire battery pack.
Solution Approach 2:
A battery management system (BMS) with microcontrollers and monitoring circuitry is introduced as an intermediary between the battery cells and the external system. The BMS continuously monitors voltage, temperature, and charge state of each CMA, preventing thermal runaway by detecting anomalies early and isolating problematic modules.
2Duration of action of stationary object
If battery cells are designed for long life, then extended operating duration is achieved, but serviceability and ease of repair are reduced
Solution Approach 1:
The battery pack is segmented into standardized cell module assemblies (CMAs) that can be independently removed and replaced. Each CMA is a self-contained unit with standardized electrical connections and mechanical interfaces, allowing field replacement without specialized tools or complex disassembly procedures.
Solution Approach 2:
The battery system transitions from a static, fixed configuration to a dynamic, reconfigurable system. CMAs can be added or removed based on capacity requirements, and individual modules can be replaced as they degrade, extending overall system life through modular refurbishment rather than complete replacement.
3Reliability
If battery management systems are implemented to monitor and regulate charging/discharging, then battery health is improved, but device complexity increases
Solution Approach 1:
The battery management function is segmented into distributed microcontrollers within each CMA rather than a single centralized system. Each microcontroller independently monitors its own CMA's voltage and temperature, reducing communication overhead and simplifying the overall control architecture while maintaining comprehensive monitoring.
Solution Approach 2:
Each CMA includes its own monitoring and protection circuitry that autonomously manages its operation. The system performs self-diagnosis and self-protection by detecting anomalies and isolating problematic modules without external intervention, reducing the complexity of external management systems.
4Ease of repair
If compartmentalized structure with tiered access is used for serviceability, then ease of repair is improved, but manufacturing complexity increases
Solution Approach 1:
The battery pack is constructed from standardized CMA modules that can be assembled in series to create different capacity configurations. This modular approach allows a single manufacturing process to produce universal modules that can be configured for various applications, reducing overall manufacturing complexity despite the compartmentalized serviceable structure.
Data Source
AI summary
A battery pack includes a housing, a positive terminal and a negative terminal, and a plurality of cell module assemblies. The positive terminal and negative terminal are each externally accessible from the housing and extend into a first compartment of the housing. The cell module assemblies are received in a second compartment of the housing, and are coupled to the positive terminal and the negative terminal through a connection extending from the second compartment into the first compartment. The first compartment is accessible through a first panel that is movably coupled to the housing through a first securing mechanism providing a first level of access. The second compartment is accessible through a second panel that is movably coupled to the housing through a second securing mechanism providing a second level of access.