Patent Application
20250140962
This disclosure relates to methods of thermal management for a battery pack.
Battery systems, specifically lithium-ion battery packs utilized in vehicles, often comprise multiple cell arrays designed to store and discharge energy. As these systems operate, they produce heat, with some areas experiencing temperature changes at varying rates due to factors like uneven distribution of energy or cooling. Traditional battery management systems may cool the entire battery pack uniformly.
In one embodiment, a battery system comprises a controller, designed and programmed to perform specific functions. This controller, when detecting from the measured temperatures of a battery pack at varying locations that these locations indicate different rates of temperature rise, has the capability to disconnect a specific cell array of the battery pack that is closest to the location having the greatest rate of temperature increase. This action is taken without disconnecting other cell arrays of the same battery pack.
Additionally, the controller can be further programmed to increase cooling in proximity to the identified location, should the measured temperatures indicate varying rates of increase. In a scenario where such temperature rises are detected, the controller is also capable of generating an alert to inform the driver or system operator. For enhanced communication and control, the controller has the capability to send the gathered temperature data to a remote server. Moreover, it can receive specific commands from this server concerning the disconnect action.
In another embodiment, a method is presented that involves elevating the cooling process near a particular location within a battery pack if that location exhibits a temperature rise rate surpassing a set threshold. This intensified cooling does not affect other locations within the battery pack, especially those experiencing temperature rise rates below this predetermined threshold or those that are distant from the said location. Should a location within the battery pack display a rate of temperature rise that breaches the threshold, the method also includes steps to disconnect the closest cell array and generate alerts. Furthermore, this method discloses the transmission of data pertaining to the rate of temperature rise to a distant server and receiving relevant commands regarding the cooling adjustment.
In yet another embodiment, a vehicle is equipped with a battery pack, consisting of numerous cell arrays, and a programmed controller. If the controller perceives that a specific location within the battery pack has reached a temperature beyond a set threshold, it has the capability to amplify the cooling in proximity to that location without impacting the cooling process of the other remote locations. This programmed controller can also disconnect the cell array closest to the exceeding location, generate alerts, and send the pertinent temperature data to a remote server. Moreover, this controller can receive indications or commands directly from the said server, enhancing its response mechanism.
Embodiments are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The figures are not necessarily to scale. Some features could be exaggerated or minimized to show details of particular components. 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.
Various features illustrated and described with reference to any one of the figures may be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.
The disclosure relates to the field of battery pack thermal management, specifically as it relates to heat reduction and efficiency. A battery pack may benefit from continuous monitoring and controlling of its temperature. Within the battery pack, there can be multiple distinct sets of arrays. In an example configuration of two arrays, the first set comprises arrays one through five, while the second set comprises arrays six through ten. In such an example configuration, thermal sensors, which are devices used to measure temperature changes, are not evenly distributed throughout all the arrays. Instead, they are selectively positioned in arrays three, four, five, six, nine, and ten. This sparse distribution can make it challenging to detect thermal events in arrays lacking a thermal sensor. Such gaps in monitoring can sometimes make a thermal event harder to detect based on cell voltage data when the voltage drop is a small amount (e.g., 0.2V) and complicated by factors like voltage rebound and infrequent data sampling (e.g., every 30 s).
This disclosure describes systems and methods of thermal event detection and their management. In one scenario if a thermal event is detected by one thermal sensor within its own array, and subsequently confirmed by another thermal sensor in an adjacent array—using a specific temperature difference (e.g., TD1=15 degC) within a particular time frame (e.g., TDT1=400 s)—then the location of the original issue can be narrowed and verified.
In another example scenario, when a single thermal sensor reading exhibits rapid fluctuations beyond a set temperature difference (e.g., TD2=20 degC) within a determined duration (e.g., TDT2=60 s), this indicates the thermal event's proximity within the same array, but farther from the thermal sensor.
In a third example scenario, if multiple thermal sensors register an increase in temperature, but none meet a set temperature threshold (e.g., TT1=65 degC), the sequence in which these thermal sensors attain a particular temperature difference (e.g., TD3=10 degC) within a designated time frame (e.g., TDT3=800 s) can reveal the distance of each from the initial fault.
Referring now to
The sets of arrays can respectively be placed in separate cooling zones or wired in parallel. In situations where they are wired in parallel, one set of arrays, perhaps the set 12, can be disconnected, leaving the other, say the set 14, fully functional.
Operably configured with the battery pack 10 is a controller 48. The controller 48 receives temperature data from the sensors and as in the scenario described above if an array, like the array 22, shows a significant temperature increase compared to others, the controller 48 can disconnect the array set 12. In other configurations the controller can be programmed to increase cooling around an array experiencing a thermal event or a specified area to counteract the temperature rise.
The controller 48 can also further be programmed to be in operative communication with a driver by sending alerts to a driver if certain temperature thresholds are breached. The controller 48 may also further be programmed to be in operative communication with a remote data server by transmitting temperature data to a remote server for off-site monitoring. This data can further be analyzed by remote teams wherein the controller 48 can be further programmed for receiving and acting on commands from the remote server, allowing for remote adjustments. It is understood that when the controller 48 is described as configured or programmed to do something, that is the functional equivalent of the controller 48 causing or commanding it to be done.
Referring now to
Referring now to
These sets can be managed within separate cooling zones or they might be wired in parallel. In scenarios where they are connected in parallel, a particular set, such as the set 52, can be independently disconnected, keeping its counterpart, the set 54, operational. Integrated with the battery pack 50 is another controller 88. This controller 88 processes the temperature data relayed from the sensors. If a particular array, such as the array 64, registers a temperature spike, the controller 88 can disconnect its associated set, the set 52. The controller 88 can also modulate the cooling within a specific vicinity if an array indicates a thermal event.
The controller 88 can be further programmed to alert the driver if temperature thresholds are exceeded. The controller 88 can also communicate with an external remote server. The controller 88 can also send temperature metrics to this server, enabling remote diagnostics. This off-site data allows external teams to interpret the data, and the controller 88 can be programmed to execute commands dispatched from this remote server. It is understood that when the controller 88 is described as being configured or programmed to do something, that is the functional equivalent of the controller 88 causing or commanding it to be done.
Moving to
Referring to
Within battery pack 90, there is a controller 128. This controller processes the temperature data from the sensors. In situations where the array 94 lacks direct monitoring readings from neighboring sensors like the sensors 122 (T6), 124 (T5), and 104 (T1) provide inferential temperature regarding the array 94. Using these readings, the controller 128 can make decisions regarding the operation of associated sets or arrays. It is understood that when the controller 128 is described as being configured or programmed to do something, that is the functional equivalent of the controller 128 causing or commanding it to be done.
When several sensors indicate a temperature rise but none cross the set mark of TT1=65 degC, the sequence in which sensors reach a difference of TD3=10 degC within TDT=800 s provides insight into the event's origin. Here, the focus is on the inboard cell of the array 94. The controller 128 can also adjust cooling in the vicinity of an indicated location without affecting other areas. The controller 128 can also disconnect specific arrays, produce alerts, and maintain communication with a remote server for data transmission and adjustments.
In
The graph plots temperature changes over time, and three lines, corresponding to the sensors 122 (T6), 124 (T5), and 104 (T1) show synchronous spikes. This synchronized uptick suggests that an event is originating near or within the array 94. The sequence in which these lines rise indicates proximity to the source of the event. Even though none of the lines cross the designated threshold of TT1=65 degC, their simultaneous and sequential rise within the parameters of TD3=10 degC over TDT=800 s is indicative of a thermal event. This pattern suggests that the source of the temperature increase is closest to the inboard cell of the array 94.
Referring to
If the outcome at block 130 is YES, the process advances to block 132, suggesting that the source of the thermal event is within the same array but not in the immediate vicinity of the detecting thermal sensor. In the event the controller at block 130 does not identify a rapid temperature rise, the controller moves to decision block 134, asking if any of the thermal sensors has recorded a thermal event. If the result is YES, it then proceeds to decision block 136, which examines if another thermal sensor, located in a different array, also observes the same event.
Should the controller at block 136 affirmatively detect an incident from another array's thermal sensor, block 138 is reached, which concludes that the origin of the event is the array associated with the first-responsive thermal sensor. However, if the outcome of block 136 is NO, the flowchart advances to decision block 140, evaluating if a group of thermal sensors achieves a particular temperature difference, such as an increase of 10 degC over 800 seconds. If this condition is met, the method progresses to operation block 142, indicating the closest point to the first-responsive thermal sensor as the likely location of the thermal occurrence. For vehicles with integrated connectivity, the event location can be communicated to a central data hub or cloud system. Specialized engineering units can then utilize this data to assess the event's scope, enabling the remote teams to determine and implement appropriate measures. Although temperature sensors are specified, their equivalent voltage sensors or any such sensors may be used with any of the embodiments.
The algorithms, methods, or processes disclosed herein can be deliverable to or implemented by a computer, controller, or processing device, which can include any dedicated electronic control unit or programmable electronic control unit. Similarly, the algorithms, methods, or processes can be stored as data and instructions executable by a computer or controller in many forms including, but not limited to, information permanently stored on non-writable storage media such as read only memory devices and information alterably stored on writeable storage media such as compact discs, random access memory devices, or other magnetic and optical media. The algorithms, methods, or processes can also be implemented in software executable objects. Alternatively, the algorithms, methods, or processes can be embodied in whole or in part using suitable hardware components, such as application specific integrated circuits, field-programmable gate arrays, state machines, or other hardware components or devices, or a combination of firmware, hardware, and software components.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of these disclosed materials. The terms “controller” and “controllers,” for example, can be used interchangeably herein.
As previously described, the features of various embodiments may be combined to form further embodiments of the disclosure that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics may be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes may include, but are not limited to strength, durability, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.
