Ultrasound Sensor for Battery Module Bolted Joint Monitoring
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Solution Overview
Problem
Conventional safety elements for bolted joints in high-voltage battery modules, such as those used in lithium-ion battery cells, are not suitable for high-current or high-voltage connections, and existing methods for assessing the preload force of these joints require disassembly, which is impractical and costly.
Innovation Solution
Incorporating an ultrasound sensor within the battery module to continuously or periodically measure the preload force of bolted joints without disassembly, allowing for timely maintenance or replacement of components, and using a battery control unit to process and evaluate the sensor data for effective monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional safety elements (encapsulated adhesives) are used to secure bolted joints, then the mechanical connection is secured, but they cannot be used for high-current or high-voltage connections in battery modules
Solution Approach 1:
The patent replaces conventional mechanical safety elements (adhesives) with an ultrasound-based sensing system that uses acoustic waves to monitor bolted joint integrity. This substitution enables non-contact, non-intrusive monitoring that is compatible with high-voltage environments while maintaining safety monitoring capabilities.
2Ease of operation
If ultrasound sensors are integrated into the battery module for continuous monitoring, then the preload force can be monitored without disassembly, but the device complexity increases
Solution Approach 1:
The patent merges the ultrasound sensor system with the existing battery module structure, integrating the sensing capability into the housing or mounting structure. This combination allows monitoring functionality to be added without requiring separate external monitoring equipment, thereby reducing overall system complexity while enabling continuous preload force monitoring.
3Ease of manufacture
If standardized safety elements are used for bolted joints, then manufacturing is simplified, but they cannot provide continuous monitoring capability
Solution Approach 1:
The patent implements a feedback mechanism where the ultrasound sensor continuously measures the preload force on bolted joints and provides real-time data to the battery control system. This feedback loop enables ongoing monitoring of joint integrity, allowing the system to detect changes in preload force and alert operators before safety issues arise, thereby preventing information loss about joint status.
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 continuous monitoring of preload forces in critical bolted joints, preventing failures and reducing maintenance costs by allowing for component replacement without disassembling larger subsystems, thus ensuring safe and efficient operation of high-voltage battery modules.
Implementation Method 1
the sensor for the purposes of determining a preload force applied to the bolted joint device is an ultrasound sensor
Data Source
AI summary
A battery module containing a plurality of battery cells electrically connected to one another in series or in parallel, two contact surfaces (14a, 14b) for the purposes of tapping off a module voltage of the battery module (10) and at least one bolted joint device (22) for the purposes of fixing a component (12), in particular a current-conducting component, of the battery module (10), wherein the at least one bolted joint device (22) is provided with a sensor (26) for the purposes of determining a preload force applied to the bolted joint device (22).