battery sensor fuse

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3A-C, a plurality of laser weld orientations and configurations are shown. 2, a laser weld 111 by a laser beam 112 between a bus bar 104 and a conductive lead 108 is shown. The battery fuse safeguards the DC connection of the inverter against an overload caused by the battery. 1, a battery array or assembly 100 is depicted.

The stitches may be arranged along an axis of the conductive lead. Embodiments of the present disclosure are described herein.

Please note – this is not a long term fix. The flow diagram 200 starts in step 202. The weld 111 may have a surface area less than the surface area of the conductive lead 108.

A plurality of battery modules 102 are arranged to form the battery array 100. The net cross-sectional area of the plurality may be between 60-70% of the cross-sectional area of the lead.

The stitches may be arranged transverse the axis of the sensor lead. Unfortunately the E60 series of BMWs have been plagued with electronics issues…many of them stemming from damage to the vehicle’s battery sensor. The vehicle of claim 13, wherein the stitches are arranged perpendicular to an axis of the conductive lead. The surface area of the weld 111 may be 60-70% of the surface area of the conductive lead 108. The stitches may be arranged transverse the axis of the sensor lead. Continuing to drive with a failed IBS usually ends up with a control message related to battery discharge and a complete shut down and “no-start” of the car. Sensor Fuse For An Electric Battery Array .

Installation of fuses may protect against short circuits.

Cheap and easy. 1 depicts a battery array configured in a series configuration; FIG. The FFC may provide a pathway for short-circuit current to leak between bus bars.

7. Considering all this, it might be a good idea to change the battery at a dealership. It is also important where to connect the wire clamps when boosting or charging the battery with a battery sensor. When the IBS fails your vehicle’s power management system can no longer determine the condition of your battery and all hell breaks loose.

Honda issued the recall (service bulletins 17-057 and 17-069) to check and, if needed, replace the battery management sensor in the 2013-2016 Honda Accord (except Hybrid). The free-falling attitude ensures that conduction will cease during a short because of physical separation of the sensor lead and bus bar.

The stitches may be arranged perpendicular to an axis of the conductive lead.

The sensor lead may be welded to a side portion of the bus bar such that tension and gravity draw the sensor lead away from the bus bar after overcurrent protection is provided. The sensor lead may be welded to a side portion of the bus bar such that tension and gravity draw the sensor lead away from the bus bar after overcurrent protection is provided.

6. One thing to note is that many of the original intelligent battery sensors were one piece units; the leads for the positive terminal and the DME were “hardwired” into the sensor (see image below).

BMW).

In step 210, the join may be checked for quality and to ensure the proper size stitch and weld surface area is used. The function of the battery sensor is particularly important in vehicles with Stop-Start feature, as the battery management system must Beginner repairs usually require very few tools, have short repair times and are simple to complete for even the most novice of mechanics. All of this works seamlessly…unless you experience an intelligent battery sensor failure. To function properly, the battery sensor must be clean and dry, and the pole terminal must be tight. JavaScript is disabled. Many electrical problems, including issues with the battery current sensor can be caused by loose or corroded battery terminals or moisture/corrosion around the battery sensor.

The stitches may be arranged perpendicular to an axis of the conductive lead.

Verify that the battery complies with locally applicable standards and directives and is intrinsically safe. The stitches 110 may have a uniform or non-uniform diameter 114. Carefully install the BMW E60 battery sensor on the negative terminal of the battery as shown below. There are some precautions when replacing the battery if a vehicle has a battery current sensor. A vehicle power system may include a battery array having at least one battery with a bus bar connected to an electrical bus. DO NOT connect it to the battery yet…only to the frame of the car. The system may further include a conductive lead of a sensor laser welded to the bus bar to form a joint defined by a plurality of stitches, a net cross-sectional area of the plurality being less than a cross-sectional area of the lead, and oriented with a free-falling attitude such that short-circuit current from the battery array melts the joint to protect the sensor and separates the lead and bus bar. For example, in some BMW vehicles, the battery is located in the side compartment in the trunk and water leaking onto the battery can damage the sensor. The vehicle of claim 13, wherein the lead is a 22-gauge wire. The battery fuse and the cabling with battery and inverter must be sized in accordance with the technical data of the DC connection ( > DC Connection for Battery).

The bulletin advises changing the battery sensor. This disclosure relates to sensor fuses for electric battery arrays.

A battery sensor is a fragile device and can also be damaged when servicing or removing the battery. The smaller cross-sectional area ensures that separation of the sensor lead and bus bar will occur under high current as the stitches of the joint melt. For a better experience, please enable JavaScript in your browser before proceeding. Although shown having uniform terminations, the conductive leads 108 may be terminated in different orientations with respect to one another. 14. batteries, ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:KIMOTO, MASAHIRO;CALLICOAT, DEBBI;NARAYANAN, RAJESH;AND OTHERS;SIGNING DATES FROM 20160721 TO 20160722;REEL/FRAME:039321/0905, Sensor fuse for an electrical battery assembly, Structure for welding electrical connecting portions to each other using laser light beam, Battery having a connecting element comprised of plural individual wires, Battery module, battery system and electric vehicle, High voltage battery system for electric vehicle, Devices and methods for connecting battery cells, Integrated voltage sense and bus bar system and method for vehicles having a traction battery, Thermal and electrical management of battery packs, Welding process for battery module components, Battery cell interconnect and voltage sensing assembly and method of manufacturing the assembly, Battery module with welded portion between terminals, Prismatic battery module with scalable architecture, Battery pack and method for protecting batteries, Electrode terminal connecting member for battery module, Fuse board and battery block equipped with same, Mounting structure for mounting temperature detection member to bus bar, wiring module, and method for manufacturing wiring module, Secondary battery and secondary battery module, Electro-mechanical connector for solar arrays, Different metallic thin plates welding method, bimetallic thin plates jointing element, electric device, and electric device assembly, Method for manufacturing battery wiring module, High-voltage energy storage module and method for producing the high-voltage energy storage module, Method of manufacturing a wiring material. Installation of standard fuses may increase manufacturing costs and introduce a single point of failure. 3A-C, a plurality of laser weld orientations and configurations are shown.

In some cars, it might be installed on the positive terminal. 3A depicts a series of stitches from a laser weld transverse to an axis of the wire; FIG.

The combinations of features illustrated provide representative embodiments for typical applications. not intended for disconnection, Articles made by soldering, welding or cutting, Safety devices for primary or secondary batteries, Batteries in motive systems, e.g. A gap may exist between each of the battery modules 102 to form the array 100. We have provided links below for all three parts so you don’t have any issues when ordering. The most difficult part is to diagnose the problem correctly, and it's not always easy. 3A discloses a conductive lead 108 laser welded 111 to a bus bar 104. Now referring to FIG. If your intelligent battery sensor has failed and you cannot start your vehicle, temporarily disable your IBS by unplugging the DME lead (the blue plug). The FFC may include several individual conductors.

The net cross-sectional area of the plurality may be between 60-70% of the cross-sectional area of the lead. verify that the battery has enough charge to re-start the vehicle. The sensor lead may be joined to the bus bar in any orientation or configuration. The Honda bulletin 16-026 for various Accord, Fit and HR-V models describes a problem where a faulty battery sensor can cause Charging System Indicator to come on with the trouble code (DTC) P154A. Installation of standard fuses may increase manufacturing costs and introduce a single point of failure.

The laser weld 111 has stitches 110 having an orientation along the axis 113 of the conductive lead 108.

At least, check your vehicle owner's manual or do some research before replacing the battery. The lead may be a 22-gauge wire. Next, install the new adapter wire to the sensor.

FIG. This data is sent to the DME (the BMW’s engine control module) which continually evaluates the condition of your battery and makes adjustments to power consumption as necessary to prolong its life. Each of the cells may be electrically joined in series to increase the electric potential between terminals of the array. 11. Hard terminations provide an unrelenting electrical connection between sensor leads capable of carrying current equivalent to the cross-sectional area of the wire.

16. complete cut of current, MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR, SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. The Repair Cost graphically displays approximately how expensive the repair will be to perform. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. If the surface area obtained has adequate fastening capabilities and is not too large, the process will end in step 214.

The conductive leads 108 may also be terminated on the bottom or sides of the bus bars 104. The charging system current is also often higher in vehicles with Stop-Start feature. Each of the cells may be electrically connected using a bus bar between individual positive and negative terminals to compound the voltage. The battery modules 102 are electrically connected in series using bus bars 104. The stitches may have a surface area equivalent to a 26-gauge wire. The conductive leads 108 may be oriented with a free-falling attitude such that separation between the bus bar 104 and conductive lead 108 occurs during a short circuit.

The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. The introduction of advanced electronics in the new 5 series put a strain on the battery, especially when the vehicle was not running.

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