Integrated Voltage Sensing Assembly for Battery Modules
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Solution Overview
Problem
The assembly process of voltage sensing units in battery modules is complex, requiring multiple members for mechanical and electrical connections, which increases system size and complicates maintenance, especially in applications like electric vehicles where compactness and stability are crucial.
Innovation Solution
A voltage sensing assembly with an upper and lower block case, each featuring mounting grooves for conductive sensors, which are connected to electrode terminals, and a connector to transmit sensed voltage to a BMS, allowing for a simple assembly method and modular structure that improves productivity and maintenance by reducing the number of members needed for coupling and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional voltage sensing units are installed using multiple members for mechanical coupling and electrical connection, then reliable voltage sensing is achieved, but the assembly process becomes complex and system size increases
Solution Approach 1:
The patent combines mechanical coupling and electrical connection functions into a single integrated voltage sensing assembly. The upper and lower block cases are coupled together to form a unified structure that simultaneously provides mechanical support and electrical connectivity to the conductive sensors, eliminating the need for separate mechanical members and wires.
Solution Approach 2:
The block cases serve multiple functions: they provide mechanical coupling between sensors and battery cells, electrical insulation, structural support, and mounting positions for conductive sensors. This multi-functionality reduces the number of separate components needed in the system.
2Stability of the object's composition
If multiple members are used for mechanical coupling and electrical connection between battery cells, then stable connections are achieved, but the number of components increases and assembly space is consumed
Solution Approach 1:
The voltage sensing assembly merges multiple connection functions into a single integrated unit. The upper and lower block cases together with the conductive sensors form one assembly that replaces what would traditionally require separate mechanical couplers, electrical connectors, and wiring components.
Solution Approach 2:
The conductive sensors are mounted within the block cases, with upper-row sensors nested in the upper block case and lower-row sensors nested in the lower block case. This nested arrangement consolidates multiple components into a compact hierarchical structure.
3Reliability
If traditional sensing units with multiple connection members are used, then electrical connection is achieved, but short circuit risks increase and maintenance becomes difficult
Solution Approach 1:
The block cases act as intermediary structures that provide electrical insulation between conductive sensors and other electrical components. The insulative material of the block cases prevents direct electrical contact between different conductive elements, serving as a protective mediator that reduces short circuit risks.
4Weight of moving object
If a compact battery module design is implemented, then weight and size are reduced, but space for mounting and connecting sensing units is limited
Solution Approach 1:
The mechanical support structure and electrical connection system are merged into a single voltage sensing assembly. The block cases provide both structural mounting positions and electrical connectivity, eliminating the need for separate mounting brackets and connection wires that would consume additional space and weight.
Solution Approach 2:
The sensors are arranged in upper-row and lower-row configurations within the vertical space of the battery module. This vertical arrangement utilizes the third dimension (height) for sensor placement, maximizing space utilization without increasing the horizontal footprint of the assembly.
Data Source
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AI summary
Disclosed herein is a voltage sensing assembly for a battery module to sense voltage of battery cells having electrode terminals formed at the upper end or the lower end thereof in a state in which the voltage sensing assembly is mounted in the battery module, the voltage sensing assembly including (a) an upper block case and a lower block case to be coupled to each other in an assembled fashion, the upper block case and the lower block case being made of an electrically insulative material, the upper block case and the lower block case being mounted to a region (front or rear) of the battery module corresponding to electrode terminal connection parts of the battery cells, (b) upper-row and lower-row conductive sensors to be connected to the electrode terminal connection parts of the battery cells, respectively, and (c) a connector to transmit voltages sensed by the conductive sensors to a battery management system (BMS), wherein the upper block case and the lower block case comprise mounting grooves, which are upwardly open, formed at positions corresponding to the electrode terminal connection parts, respectively, the upper-row conductive sensors are connected to the upper-row electrode terminal connection parts in a state in which the upper-row conductive sensors are mounted in the mounting grooves of the upper block case, and the lower-row conductive sensors are connected to the lower-row electrode terminal connection parts in a state in which the lower-row conductive sensors are mounted in the mounting groove of the lower block case.