Shunt Structure for Charge-Discharge Cycler
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Solution Overview
Problem
Conventional shunts used in battery charging/discharging tests are prone to cracking under torque, leading to changes in resistance, inaccurate current measurement, and potential safety issues such as explosion or overheating, especially during rapid charge-discharge cycles, and suffer from noise problems and saturation issues at high currents.
Innovation Solution
A system for charge-discharge cycler with an improved shunt structure featuring a current measuring circuit unit and a current conducting member with a shunt connecting groove and side connecting groove for enhanced bonding, a Kelvin sensing terminal, and a cooling fan to stabilize current measurement and reduce noise, allowing precise current control and accurate battery testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a shunt is made in an elongated form and connected by welding, then the shunt can measure current, but the welding part cracks under torque causing resistance changes
Solution Approach 1:
The shunt connection structure is divided into multiple segments: a shunt body, a shunt connecting groove for insertion, and a side connecting groove for welding. This segmentation allows the shunt to be mechanically inserted and then welded at multiple points, distributing the stress and preventing crack propagation that would occur in a single elongated welded joint.
Solution Approach 2:
The connection structure combines different materials and joining methods: the shunt body (manganese material) is inserted into a copper current conducting member and connected through silver or lead welding at the grooves. This composite approach leverages the mechanical fit of insertion combined with the electrical and structural properties of welding, creating a more reliable connection than welding alone.
2Measurement precision
If silver soldering is used to connect shunt to current conducting member, then electrical connection is achieved, but cracks cause resistance changes and measurement errors
Solution Approach 1:
The shunt connecting groove and side connecting groove are pre-formed in the current conducting member to provide a mechanical guide and support structure before welding. This pre-positioning ensures proper alignment and distributes welding stress, preventing cracks in the silver soldering joints that would otherwise cause resistance changes and measurement errors.
Solution Approach 2:
The copper current conducting member acts as an intermediary between the manganese shunt and the measurement circuit. The shunt is inserted into the current conducting member, and the side connecting groove provides an intermediate welding surface that stabilizes the connection, preventing direct stress transmission to the silver soldering joints.
3Device complexity
If conventional shunt structure is used, then simple construction is maintained, but noise problems occur and saturation happens at 50 A or more
Solution Approach 1:
The connection structure transitions from a simple linear elongated shunt to a three-dimensional configuration with grooves formed at specific positions and orientations. The shunt connecting groove is formed at one end while side connecting grooves penetrate the current conducting member perpendicular to the main axis, creating a multi-dimensional connection that reduces noise and prevents saturation at high currents while maintaining structural simplicity.
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
The system achieves improved precision and accuracy in current control during battery testing, simulates real driving conditions for electric vehicle batteries, and prevents overheating or explosion risks by stabilizing current measurement and reducing noise, enabling reliable high-current testing.
Implementation Method 1
a cooling fan for cooling the heat from a first shunt and a second shunt
Implementation Method 2
a current measuring circuit unit for measuring a current wave form of charge-discharge with a voltage across a shunt
Data Source
AI summary
Disclosed is a system for charge-discharge cycler, particularly to a system for charge-discharge cycler in which a structure of a shunt is improved to improve performance/accuracy of a current control as a key component of an instrument for testing a secondary battery charge-discharge. A system for charge-discharge cycler has the effect of improving the degree of precision/performance of the current control during a charge/discharge inspection of the secondary battery, thereby raising the standard of development/aspect of the secondary battery and developing a charge/discharge performance tester of high performance.