I am facing various design challenges with a project that I am currently working on.
I've been trying to figure out a way to build a circuit that detects open circuit, short circuit, and battery reversal. I am dealing with a battery assembly of six nickel-metal hydride battery cells in series which has a binder connector consisting of 7 pins (battery baton).
When the batteries are fully charged, the voltage is a maximum of 9V, however, in the event of the batteries being fully discharged, the voltage is 5V. I have found a way to eliminate reverse polarity as I can use a P-Channel MOSFET.
I am using an Arduino microcontroller to carry out pin checks between pins that may be short-circuited. In order to detect an open circuit (pins that are floating), I can possibly build a current monitor circuit that uses a shunt resistor and the current flowing through the voltage being dropped across the shunt resistor can be measured.
I have attached the wiring configuration for the battery baton binder connector ends for two different battery batons and also a circuit that I have thought of that may do the trick for now.