Modular thermal management system

Abstract

A modular and on-demand battery thermal management system (BTMS) (126) for an electric machine (100) or a fixed energy storage solution with a battery (118) is disclosed. The BTMS (126) may include one or more independently operable BTMS modules (202), where each BTMS module (202) may be configured to cool a corresponding component of the electrical machine (100), such as a particular battery pack (208, 210). Each BTMS module (202) may in turn include a plurality of BTMS units (204) that cool a coolant to be delivered to a component to be cooled within the electrical machine (100). The individual BTMS units (204) may be independently operated by the BTMS controller (128) based at least in part on a cooling need for the component to be cooled. The BTMS controller (128) is also configured to control the pump (216) and the valve (302) to appropriately direct coolant to the BTMS unit (204) operating in a modular manner.

Description

Technical Field

[0001] The present invention relates to a modular thermal management system. More specifically, the present invention relates to a modular thermal management system that provides variable levels of battery cooling. Background Art

[0002] Machines such as mining trucks, loaders, bulldozers, compactors, or other construction or mining equipment are beginning to be powered by electricity such as on-board batteries. Machines powered by electricity are used in construction, building, mining, and other activities. For example, mining trucks are often used to transport mined materials from a mine. It is desirable to use alternative energy, such as electricity stored in a battery, to power these types of machines. For example, electric machines can benefit from reduced emissions of carbon (e.g., carbon dioxide), particulate matter (e.g., diesel soot), nitrogen oxides (e.g., NOx), and / or organic (e.g., volatile organic compounds (VOC)) emissions relative to traditional fuel (e.g., diesel, gasoline, etc.) powered machinery.

[0003] While electric machinery can provide various improvements, such as environmental advantages, electric machinery can also pose new challenges, such as thermal management of one or more batteries of the electric machinery. The batteries of electric machines typically have a more narrow thermal operating range than other components of the electric machine. For example, the operating temperature range in which the battery can operate can be about 20 °C or lower. For example, the ideal range of battery operating temperature can be between 10 °C and 30 °C. The above temperature values are merely examples, and the actual operating temperature values of various batteries can be different from the above values. A significant deviation outside the acceptable operating temperature range of the battery of an electric machine can result in a reduction in battery life, and sometimes a significant reduction, as well as the likelihood of battery failure. Therefore, failure to control the operating temperature of the battery of an electric machine can result in significant costs and / or downtime, which manifests as additional costs and / or delays in construction, mining, and / or farming tasks.

[0004] The batteries of electric machines also present challenges in controlling the battery temperature when operating under multiple operating conditions. For example, when a large amount of charge is drawn from the battery, such as when the electric machine is used to perform a particularly energy-consuming task, the battery can generate significantly more heat than when the electric machine is stationary or performing a less energy-consuming task. Therefore, the cooling requirements for operating the battery can be variable, depending on the task that the electric machine is performing. Additionally, the battery of an electric machine may need to be cooled when the battery is being charged.

[0005] A mechanism for thermal management of a battery is described in U.S. Patent No. 8,734,975 (hereinafter referred to as the "‘975 reference"). The ‘975 reference describes heating and cooling individual battery cells within each battery module 14 using a liquid coolant from a thermal management system 10. The ‘975 reference describes that the thermal management system 10 includes a plurality of modular manifold sections 16 adapted to be connected to each cooling channel or heat exchanger fin for each battery cell. However, the systems and methods described in the ‘975 reference do not relate to controlled variable cooling of the battery. Thus, the disclosure of the ‘975 reference does not describe how to control the temperature of the battery within an operating range when the battery operates under a wide range of conditions with highly variable heat output levels.

[0006] Embodiments of the present invention are directed to overcoming one or more of the above deficiencies. Summary of the Invention

[0007] In one aspect of the present invention, a machine includes: an electric motor for propelling the machine; a battery configured to power the electric motor; a battery controller configured to report a temperature associated with the battery; and a battery thermal management system (BTMS). The BTMS includes a coolant line and a BTMS module, the coolant line being configured to circulate coolant to cool the battery, and the BTMS module having a first BTMS unit and a second BTMS unit, wherein the first BTMS module is configured to provide coolant cooled by the first BTMS unit and the second BTMS unit to cool the battery. The BTMS further includes a BTMS controller configured to receive a temperature level associated with the battery and independently operate the first BTMS unit and the second BTMS unit.

[0008] In another aspect of the present invention, a method includes circulating coolant from a first battery pack to a first battery thermal management system (BTMS) module configured to cool the coolant via a coolant line and using a first pump, wherein the first BTMS module includes a first BTMS unit and a second BTMS unit. The method further includes determining that the first BTMS unit is to operate actively to cool the first battery pack and causing the first BTMS unit to operate actively. The method further includes: circulating coolant from a second battery pack to a second BTMS module configured to cool the coolant via the coolant line and using a second pump, wherein the second BTMS module includes a third BTMS unit and a fourth BTMS unit; determining that the third BTMS unit will operate actively to cool the first battery pack; and causing the third BTMS unit to operate actively.

[0009] In another aspect of the present invention, a battery thermal management system (BTMS) includes a first BTMS module configured to cool a first battery pack, the first BTMS module having a first BTMS unit and a second BTMS unit, wherein the first BTMS unit and the second BTMS unit are capable of independent operation, and wherein each of the first BTMS unit and the second BTMS unit is configured to actively or passively cool a coolant. The BTMS further includes a second BTMS module configured to cool a second battery pack, the second BTMS module having a third BTMS unit and a fourth BTMS unit, wherein the third BTMS unit and the fourth BTMS unit are capable of independent operation, and wherein the third BTMS unit and the fourth BTMS unit are configured to actively or passively cool the coolant. The BTMS also includes a BTMS controller configured to receive a temperature level associated with at least one of the first battery pack or the second battery pack and cause at least one of the first BTMS module or the second BTMS module to operate. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a schematic diagram of an exemplary electric machine having a battery thermal management system (BTMS) according to an example of the present invention.

[0011] Figure 2 is according to an example of the present invention depicting having Figure 1 the environment of a battery thermal management system (BTMS) of the electric machine depicted in

[0012] Figure 3 is according to an example of the present invention depicting having Figure 2 the environment of a BTMS unit within a battery thermal management system (BTMS) of

[0013] Figure 4 is according to an example of the present invention depicting having Figure 2 the control system of a battery thermal management system (BTMS) of

[0014] Figure 5 is according to an example of the present invention depicting an example method for providing Figure 2 a battery thermal management system (BTMS) of

[0015] Figure 6 is according to an example of the present invention depicting an example method for operating Figure 2 a battery thermal management system (BTMS) of DETAILED DESCRIPTION

[0016] Wherever possible, the same reference numerals are used in all the drawings to refer to the same or like parts.

[0017] Figure 1 FIG. is a schematic view of an exemplary electric machine 100 according to multiple instances of the present invention. Although the electric machine 100 is depicted as a mining truck type machine, it can be any suitable machine, such as any type of loader, bulldozer, dump truck, skid steer loader, excavator, compactor, backhoe, combine harvester, crane, drilling equipment, tank, trencher, tractor, any suitable stationary machine, any kind of generator, locomotive, marine engine, combinations thereof, and so on. The electric machine 100 is configured to be propelled using electricity. However, in some cases, in addition to electricity, the electric machine can also be configured to be propelled using other fuels, such as diesel, gasoline, hydrogen, and / or hydrogen-containing compounds, such as various hydrocarbons (methane, ethane, propane, butane, pentane, hexane, combinations thereof, etc.), compressed natural gas (CNG), natural gas, liquefied natural gas (LNG), combinations thereof, and so on. In other words, the systems and methods discussed herein can be applied to both electric machines 100 and hybrid machines.

[0018] The electric machine 100 is shown as a mining truck, which is used, for example, to move mined materials, heavy construction materials, equipment, and / or the like. The electric machine 100 can be used in road construction, building construction, mining, paving, and / or other construction applications. For example, the electric machine 100 is used in situations where it is necessary to transport materials such as mineral ores, loose stones, gravel, soil, sand, concrete, and / or other materials of the construction site on the surface 102 of the construction site. As discussed herein, the electric machine 100 can also be in the form of a bulldozer, where the electric machine 100 is used to redistribute and / or move materials on the surface 102. In addition, the electric machine 100 can be in the form of a compactor, which can traverse the surface 102 and impart a vibrating force to compact the surface 102. Such a compactor includes a drum that can vibrate to apply energy to the surface 102 for compaction. For example, an electric compactor is configured to compact newly deposited asphalt and / or other materials disposed on and / or associated with the surface 102, such as to construct a road or a parking lot. As yet another example, the electric machine 100 can be in the form of a combine harvester for harvesting grains. It should be understood that the electric machine 100 can be in the form of any other type of suitable construction, mining, farming, military, and / or transportation machine. For the sake of brevity, without discussing each type of construction and / or mining machinery individually, it should be understood that the electric drive mechanism described herein is configured for a variety of electric machines 100.

[0019] As Figure 1As shown, the electric machine 100 includes a frame 104 and wheels 106. The wheels 106 can be mechanically coupled to a powertrain (not shown) to propel the electric machine 100. When the wheels 106 of the electric machine 100 are rotated, the electric machine 100 traverses a surface 102. Although shown in Figure 1 as having hubs with rubber tires, in other examples, the wheels 106 can alternatively be presented in the form of drums, chain drives, combinations thereof, and the like.

[0020] The electric machine 100 can include a hydraulic system 108 that moves a dump box 110 or other movable elements configured to move, lift, carry, and / or dump materials. For example, the dump box 110 is used to pick up and transport dirt or mined ore from one location on the surface 102 to another location on the surface 102. The dump box 110 is actuated by the hydraulic system 108 or any other suitable mechanical system. In some cases, the hydraulic system 108 is powered by an electric motor (not shown), such as by a hydraulic pump (not shown) of the hydraulic system 108. It should be noted that in other types of machines (e.g., machines other than mining trucks), the hydraulic system 108 can be in a configuration different from the one shown here, can be used to operate elements other than the dump box 110, and / or can be omitted.

[0021] Continuing to refer to Figure 1 , the electric machine 100 can include an operator station 112. The operator station 112 is configured to house an operator (not shown). The operator located in the operator station 112 interacts with various control interfaces and / or actuators within the operator station 112 to control the movement of various components of the electric machine 100 and / or the overall movement of the electric machine 100 itself.

[0022] Thus, the control interfaces and / or actuators within the operator station 112 allow the propulsion of the electric machine 100 to be controlled by controlling the operation of one or more engines 114. The engine controller 116 can be controlled based on operator input received at the operator station 112. The engines 114 can be powered by a battery system or battery 118 through a battery controller 120. As used herein, the battery 118 can refer to a battery system, battery(batteries), or any suitable collection of electrochemically energy storage devices arranged in any suitable manner and having any suitable partitioning thereon. In some examples, one or more engines 114 can be directly coupled to the corresponding wheels 106. In other cases, one or more engines 114 can be mechanically coupled to the corresponding wheels 106 via one or more mechanical couplings (such as a powertrain (not shown)).

[0023] The engine 114 can be of any suitable type, such as an induction motor, a permanent magnet motor, a switched reluctance (SR) motor, combinations thereof, and so on. The engine 114 has any suitable voltage, current, and / or rated power. The engines 114, when operating together, are configured to propel the electric machine 100 according to the needs of the task to be performed by the electric machine 100. The motor controller 116 includes one or more control electronics to control the operation of the engine 114. In some cases, each engine 114 can be controlled by its own motor controller 116. In other cases, all of the engines 114 of the electric machine 100 can be controlled by a single motor controller 116. The motor controller 116 can further include one or more inverters or other circuitry to control the energization of the flux generating elements (e.g., coils) of the engine 114. The engines 114 are mechanically coupled to various driveline components, such as drive shafts and / or axles, or directly to the wheels 106, to rotate the wheels 106 and propel the electric machine 100. The driveline can include any other kind of components, including but not limited to differentials, one or more couplings, constant velocity (CV) joints, and so on. Although not shown herein, there can be one or more engines 114 that are not used for propelling the electric machine 100 but are used to operate pumps and / or other auxiliary components, such as for operating the hydraulic system 108.

[0024] According to an example of the present invention, power for energizing the engine 114 is received from the battery 118. As discussed herein, the battery 118 as referred to herein can represent any suitable level of a battery system, a battery bank, and / or an electrolytic cell bank. As shown, the battery 118 is on-board or carried by the electric machine 100. In some exemplary cases, the engine 114 can operate only based on the power stored in the battery 118. In other example cases, the engine 114 can operate from the battery 118 and / or an off-board energy source (e.g., an electrified trolley line from which the electric machine 100 can draw power). In yet another example case, the engine 114 can be operated by the energy stored in the battery 118 and one or more other on-board power sources (such as a fuel cell). For example, in a fuel cell-powered machine, the battery 118 can be used to provide peak power levels because fuel cells tend to provide a steady power level that is challenging for quickly increasing and / or decreasing in response to power demands. According to an example of the present invention, the battery 118 (alone or together with other power sources) can provide power for operating the engine 114 of the electric machine 100 and / or other power-consuming components (such as power electronics, controllers, cooling systems, displays, actuators, sensors, etc.).

[0025] The battery 118 can be of any suitable type and capacity. For example, the battery can be a lithium iron phosphate (LiFePO 4 or LFP) battery, a lithium-ion battery, a lead-acid battery, an aluminum-ion battery, a flow battery, a magnesium-ion battery, a potassium-ion battery, a sodium-ion battery, a metal hydride battery, a nickel-metal hydride battery, a cobalt-metal hydride battery, a nickel-cadmium battery, any type of wet cell, any type of dry cell, a gel cell, combinations thereof, and so on. As discussed herein, the battery 118 can be suitable for liquid cooling. The battery 118 can be organized as a collection of electrochemical cells that are arranged to provide the voltage, current, and / or power requirements of the engine 114. In some cases, the energy capacity of the battery 118 can be sufficient to power the electric machine 100 for several hours or even an entire day. In other cases, the capacity of the battery 118 can be such that the battery can power the electric machine 100 at any time from about 30 minutes to about 3 hours. In additional cases, the battery 118 can store only enough energy to power the electric machine 100 for about 30 minutes or less. It should be understood that the above values are examples, and the present invention contemplates any suitable value for the energy capacity of the battery 118, including ranges outside of the above ranges.

[0026] Regardless of the capacity, type, or whether the battery 118 is the sole energy source of the electric machine 100, the battery 118 can be organized in any suitable manner. For example, the battery 118 includes any number of battery cells (not shown), which can be organized into any number of different battery modules (not shown), which can be further organized into battery packs ( Figure 1 not shown in). For example, there can be a single battery pack for the battery 118. In other cases, the battery 118 can include two separate battery packs. In other cases, three, four, or indeed any suitable number of battery packs or other separators can be present within the battery 118. Although the present invention uses the term "battery pack", it should be understood that the present invention contemplates other terms for parts of the battery, such as parts that include a collection of batteries. Some of these other parts of the battery 118 can be groups, packs, parts, modules, etc. In other cases, the battery 118 can actually be a battery system having multiple batteries therein. Again, with respect to the present invention, the separators (e.g., battery packs) of the battery 118 or the battery system can be independently temperature controlled.

[0027] The battery controller 120 can be configured to allow the battery 118 to supply power to various components of the electric machine, such as the engine 114, electronics, controller, etc. of the electric machine 100. The battery controller 120 can also be configured to provide a variety of information, such as providing information related to the battery 118 to other controllers of the electric machine 100. In some instances, the battery controller 120 can be configured to provide individual information about individual modules, battery cells, or other sections or partitions of the battery 118. In some cases, the battery controller 120 can periodically send data about the battery 118 to another controller or other entity. In the same or other cases, the battery controller 120 can send data about the battery when requested to do so (e.g., by another controller of the electric machine 100).

[0028] In an example, the battery controller 120 can determine information about the battery 118 from any suitable source, such as any kind of sensor, such as a temperature sensor. For example, the battery 118 can have an associated temperature sensor (not shown), and the temperature sensor can provide the temperature of individual modules and / or cells of the battery 118 to the battery controller 120. The battery controller 120 can receive signals of any kind from these sensors associated with the battery and thereby determine physical measurements. For example, the battery controller 120 can receive a signal from a thermocouple of a battery cell and determine the relevant temperature of the battery cell based on the received signal from the thermocouple. In addition to the temperature of the batteries within the battery 118, the battery controller 120 can be configured to receive sensor signals associated with a cooling fluid (e.g., coolant) used to cool the battery 118. For example, the battery controller 120 can be configured to determine the coolant inlet temperature, coolant outlet temperature, coolant inlet pressure, and / or coolant outlet pressure of any coolant used to cool the battery 118 during operation and / or charging.

[0029] The electric machine 100 includes an electronic control module (ECM) 122 that controls various aspects of the electric machine 100. The ECM 122 is configured to receive the battery state (e.g., state of charge (SOC) or other charge-related metrics) from the battery controller 120, operator signal(s), such as an accelerator signal, at least in part based on the interaction of the operator with one or more control interfaces and / or actuators of the electric machine 100. In other cases, the ECM 122 may receive control signals from a remote control system via wireless signals received via the antenna 124. The ECM 122 uses the operator signal to generate command signals that control various components of the electric machine 100, regardless of whether the signals are received from an operator in the operator station 112 or from a remote controller. For example, the ECM 122 may control the engine 114 via the motor controller 116, the hydraulic system 108, and / or the steering of the electric machine 100 using a respective controller (not shown). It should be understood that the ECM 122 may control any other type of subsystem of the electric machine 100 not explicitly discussed herein in order to provide the operating capabilities discussed herein for the electric machine 100.

[0030] The ECM 122 may include a single or multiple microprocessors, field programmable gate arrays (FPGAs), digital signal processors (DSPs), and / or other components configured to control the electric machine 100. Many commercially available microprocessors may be configured to perform the functions of the ECM 122. Various known circuits are operably connected to the ECM 122 and / or other circuits of the electric machine 100 and / or are otherwise associated with the ECM 122 and / or other circuits of the electric machine 100. Such circuits and / or circuit components may include power circuits, inverter circuits, signal conditioning circuits, actuator driver circuits, etc. The present invention is in no way limited to the type of the ECM 122 or the shown positioning of the ECM 122 and / or other components relative to the electric machine 100. The ECM 122 is configured to control the use of energy from the battery 118 and may cooperate with other controllers of the electric machine 100 in a manner that enhances the range or performance of the electric machine 100. In some cases, the ECM 122 may also provide control functions for cooling the battery 118, which is discussed herein.

[0031] The electric machine 100 further includes a battery thermal management system (BTMS) 126. The BTMS 126 is configured to supply coolant to the battery 118 to maintain the temperature of the battery 118 and / or portions thereof within an acceptable operating range. The operating range of the battery 118 to which the temperature can be controlled by the BTMS 126 can be a range that provides a reduced chance of failure of the battery 118 and / or a greater chance of long-term life of the battery 118. Overheating of the battery 118, particularly the type of battery 118 used on the electric machine 100, can result in failure of the battery (such as explosion, leakage, etc.) and / or a reduction in the overall life of the battery 118. For example, a high operating temperature of the battery 118 may cause accelerated degradation of the electrolyte and / or electrodes of the battery 118. To prevent battery failure and increase the operating life of the battery 118, according to the disclosure herein, the BTMS is used to control the operating temperature of the battery. It should also be noted that although the BTMS 126 is discussed in the context of thermal management of the battery 118, the BTMS can also be used for thermal management of any suitable component of the electric machine, such as power electronics, controllers, hydraulic components, etc.

[0032] The BTMS 126 can include a BTMS controller 128 that provides control functions for modular and controllable cooling of the battery 118 based on the thermal requirements of the battery 118. The BTMS 126 has selectable cooling levels, as will be discussed in more detail in connection with Figure 2 The BTMS controller 128 is configured to receive temperature or other operating information from one or more other entities (such as the battery controller 120) and thereby determine the cooling requirements of the BTMS 126. For example, the BTMS controller 128 may receive a specific maximum battery cell temperature level of a specific module of the battery 118. The BTMS controller 128 can then operate a portion of the BTMS 126 at a level commensurate with the cooling requirements of the battery pack, as determined from the indication of the received maximum battery temperature. The BTMS 126 can be modular and provide variable levels of cooling power, as indicated by the BTMS controller 128. In this way, the battery 118 is not cooled too much or too little, resulting in dynamic cooling control to a relatively tight range. It should be noted that in alternative examples, as disclosed herein, the functions of the BTMS controller 128 can be performed by other controllers of the electric machine, such as the ECM 122.

[0033] The electric machine 100 further includes any number of other components within the operator station 112 and / or at one or more other locations on the frame 104. These components include, for example, one or more of a position sensor (e.g., global positioning system (GPS)), an air conditioning system, a heating system, a communication system (e.g., radio, Wi-Fi connection), a collision avoidance system, sensors, cameras, etc. These systems are powered by any suitable means, such as by using a direct current (DC) power supply powered by the battery 118 and / or any other source. The BTMS 126 as disclosed herein can be used to control the temperature of any of the foregoing components of the electric machine 100.

[0034] It should be understood that the electric machine 100 as discussed herein provides an improved modular BTMS 126 that can provide variable cooling levels to any number of modules of the battery 118. Thermal management of the battery 118 using the BTMS 126 can be performed when the electric machine 100 is operating, idling, shut down, and / or when the battery 118 is being charged. The BTMS controller 128 can receive, for example, various information about the battery 118 and / or its modules from the battery controller 120, and control the temperature of the battery 118 and / or its modules within a desired operating range. As needed, the BTMS controller 128 can engage multiple units of the BTMS 126 to control the temperature of the battery 118 within a desired temperature range. As discussed herein, good control of the operating temperature of the battery 118 can result in a greater lifespan of the battery 118 and a reduced chance of failure of the battery 118.

[0035] Although the BTMS 126 is discussed herein as part of the electric machine 100, it should be understood that the electric machine 100 is only one application of the BTMS 126. As disclosed herein, the BTMS 126 can be used for any suitable energy storage solution, whether mobile or stationary. For example, as disclosed herein, the BTMS 126 can be deployed for stationary energy storage and a two-way power grid. Additionally, the BTMS 126 can be used for other mobile solutions in addition to the electric machine 100.

[0036] Figure 2 is depicted according to an example of the present invention having Figure 1Schematic diagram of the environment 200 of the battery thermal management system (BTMS) 126 of the electric machine 100 depicted therein. The BTMS 126 can be organized in one or more BTMS modules 202(1), …, 202(N), which will be referred to as a single BTMS module 202 hereinafter, or multiple BTMS modules 202. Each BTMS module can include multiple BTMS units 204(1), 204(2), 204(3), …, 204(M), which will be referred to as a single BTMS unit 204 hereinafter, or multiple BTMS units 204. The BTMS unit 204 can be fluidly connected to a coolant line 206 in which coolant is guided.

[0037] The BTMS 126 can be used to control the temperature of the battery 118. The battery 118 is depicted as having two battery packs 208, 210. In other cases, the battery 118 can have any number of different packs. In some examples, each BTMS module 202 can correspond to the battery packs 208, 210. In other words, each BTMS module 202 can be dedicated to cooling the corresponding battery packs 208, 210. In other cases, more than one BTMS module 202 can be used to cool a single battery pack 208, 210. In other cases, one BTMS module 202 can be used to cool more than one battery pack 208, 210.

[0038] Each battery pack 208, 210 can be a partition of the battery 118. The battery packs 208, 210 can include multiple battery cells of the battery 118. In some cases, all the battery packs 208, 210 of a particular battery 118 can have the same size (e.g., contain the same number of constituent batteries, provide substantially the same voltage, current, power, etc.). In other cases, the battery packs 208, 210 of the battery 118 can have different sizes. Additionally, in some cases, each of the battery packs 208, 210 can have its own battery controller 120. In other cases, the battery 118 can have a single battery controller 120 that provides control, measurement, and reporting / communication functions for all the battery packs 208, 210 of the battery 118. Although not shown here, the battery packs 208, 210 can include any number of sensors, such as temperature sensors (e.g., thermocouples). In some cases, the sensors can indicate the temperature of the individual cells of the battery 118 to the battery controller 120.

[0039] The battery controller 120 may be configured to determine the temperature of the cells within the battery 118. For example, the battery controller 120 may be configured to determine the temperature of the cells within each of the battery packs 208, 210. Additionally, it should be noted that although two battery packs 208, 210 are shown herein, in other examples, any number of different battery packs 208, 210 may be present, and the battery controller 120 may be configured to determine the temperature associated with any number of battery packs 208, 210. Further, the battery controller 120 may determine temperature statistics associated with an individual battery pack 208, 210 and report the temperature statistics to the Battery Thermal Management System (BTMS) controller 128.

[0040] As an example, the battery controller 120 may receive a plurality of battery cell temperatures associated with the battery pack 208, and determine the highest and lowest temperatures of the battery cells (e.g., the range of the battery cell temperatures), and report those high and low battery cell temperatures to the BTMS controller 128. Then, the BTMS controller 128 may determine the cooling requirement of the battery pack 208 based at least in part on the high and low battery temperatures received from the battery controller 120. It should be understood that the cooling requirements of the battery packs 208, 210 may be determined based at least in part on other temperature measurements associated with the battery packs 208, 210. The BTMS controller 128 may further operate the BTMS module 202(1) corresponding to the battery pack 208 such that the BTMS module 202(1) provides the cooling requirement of the battery pack 208. In some cases, the BTMS controller 128 may determine how many and / or which BTMS units within the BTMS module 202(1) are actively operating to provide the cooling requirement of the battery pack 208. The battery controller 120 and / or the BTMS controller 128 may perform a similar process for the battery module 210 and the corresponding BTMS module 202(N).

[0041] When operating the BTMS module 202, for example, by actively or passively operating one, some, or all of the BTMS units 204 within the BTMS module 202, coolant can be conveyed through the coolant line 206 to the heat exchangers 212 adjacent to the battery packs 208, 210 to cool the corresponding battery packs 208, 210. After the coolant has flowed through one or more of the heat exchangers 212, the coolant can be directed through the coolant line 206 to the coolant tank 214. The coolant tank 214 can serve as a coolant reservoir or storage tank, and the coolant can be pumped from the coolant reservoir or storage tank according to the needs of the BTMS 126, where the needs of the BTMS 126 are determined by the temperature of the battery 118 and / or its battery packs 208, 210. The coolant pump 216 can be configured to pump the coolant to the BTMS module 202 and / or individual BTMS units 204 and / or through the BTMS module 202 and / or individual BTMS units 204. The BTMS controller 128 can also control the operation of the coolant pump 216 to provide the correct amount of coolant flow through the BTMS module 202, BTMS units 204, and / or heat exchangers 212.

[0042] As shown, the BTMS modules 202 can be arranged in parallel, where each BTMS module 202 has its own coolant inlet and outlet. In other words, the coolant flow in one BTMS module 202 may have no effect on the coolant flow through another BTMS module 202. Within each BTMS module 202, the BTMS units 204 can be arranged in parallel. In other words, when multiple BTMS units 204 within the BTMS module 202 are turned on or actively cooling the coolant, the coolant can flow through all of the BTMS units 204 of the BTMS module 202. Each BTMS unit 204 of the BTMS module 202 can operate in an active mode or a passive mode. When operating in the active mode, the BTMS unit 204 can actively cool the coolant passing through it. When operating in the passive mode, the coolant can pass through the radiator or other heat sink of the BTMS unit 204. It can be determined by the BTMS controller 128 and at least partially based on the temperature data associated with the battery 118 and / or the battery packs 208, 210 whether an individual BTMS unit operates in the active mode or the passive mode. In some cases, whether an individual BTMS unit operates in the active mode or the passive mode can also be determined at least partially based on environmental conditions, such as received by the BTMS controller from the ECM 122 or other controllers. The operation of each BTMS unit 204 will be discussed in more detail. Figure 3 Discuss the operation of each BTMS unit 204 in more detail.

[0043] The coolant pump 216 can be operated, for example, by the BTMS controller 128 to pump a sufficient amount of coolant through each BTMS module 202. Although described as each BTMS module 202 having its own coolant pump 216, it should be understood that alternatively, multiple BTMS modules 202 can share a single coolant pump 216, or multiple coolant pumps 216 can pump coolant through a single BTMS module 202. Although shown herein as being disposed upstream of the BTMS module 202, the coolant pump can alternatively and / or additionally be disposed downstream of the BTMS module 202 and / or even disposed within the BTMS module 202.

[0044] The BTMS controller 128 can be configured to control the coolant pump 216 based on the cooling requirements of the battery packs 208, 210 and / or the cooling level of the corresponding BTMS module 202. For example, the coolant pump 216 can be operated to pump additional coolant, such as additional coolant from the coolant tank 214, at least in part based on the cooling requirements of the corresponding battery packs 208, 210. In some cases, there can be a certain level of coolant flow for each BTMS unit 204 that is operating (e.g., in the active mode). In other words, the BTMS controller 128 can direct the coolant pump 216 to increase the coolant flow rate by a certain amount for each BTMS unit 204 of the activated BTMS module 202.

[0045] As Figure 2 shown, it should be noted that each of the battery packs 208, 210 can be independently cooled using its own dedicated BTMS module 202. Compared to conventional cooling systems, this allows for better and more robust control of the temperatures of the different battery packs 208, 210 of the battery 118. Additionally, within the BTMS module 202, there can be variable selectable cooling levels by choosing the number of BTMS units 204 to operate actively within the BTMS module 202. By activating the BTMS units 204 of the BTMS module 202 according to the cooling requirements of the corresponding battery packs 208, 210, the operating temperature of the battery 118 can be tightly controlled, resulting in more efficient operation of the battery 118 and a longer lifespan of the battery 118.

[0046] Figure 3 is an example according to the present invention depicting having Figure 2Schematic of the environment 300 of the battery thermal management system (BTMS) unit 204 within the BTMS126. As shown, two specific BTMS units 204(1), 204(M) within a particular BTMS module 202 are depicted, as well as example component parts of the BTMS units 204(1), 204(M). Although two specific BTMS units 204(1), 204(M) are shown, any number of BTMS units 204 can be present within the BTMS module 202, as indicated by the ellipse between the BTMS units 204(1), 204(M).

[0047] As discussed herein, the BTMS units 204 of the BTMS module 202 can operate independently or in combination with other BTMS units 204 of the BTMS module 202. A separate BTMS module can operate in an active mode (e.g., using refrigeration operation) or a passive mode (e.g., using flow through a radiation element). In some cases, all of the BTMS units 204 within a particular BTMS module 202 can be substantially the same, e.g., having similar or the same model number, manufacturer, type, capacity, combinations thereof, etc. In other cases, different BTMS units 204 can be provided within the BTMS module 202, e.g., different types and / or models.

[0048] The BTMS unit 204 can be any suitable type capable of providing cooling of the fluid coolant within the coolant line 206. For example, the BTMS unit 204 can be or include any suitable refrigeration system, e.g., any proprietary refrigeration system and / or any suitable commercially available refrigeration system.

[0049] The coolant flow within each BTMS unit 204 can be controlled by one or more valves 302. For example, as shown, the valves 302 can be arranged such that the coolant can selectively flow into the cooler 304. The BTMS unit 204 can also include a refrigerant line 306, a compressor 308, a condenser 310, an expansion valve 312, a BTMS unit controller 314, and a radiator 316. When the BTMS unit 204 operates in the active mode, the refrigerant can flow through the refrigerant line 306, as well as the cooler 304, the compressor 308, the condenser 310, and the expansion valve 312. When the BTMS unit 204 operates in the passive mode, the refrigerant may not flow through the above elements. Instead, in the passive mode, the coolant can flow through the radiator 316. It should be understood that although a particular refrigeration unit has been discussed with respect to the BTMS unit 204, the present disclosure contemplates using any suitable type or refrigeration system for the BTMS unit 204.

[0050] In some instances, valve 302 (e.g., in the form of a three-way valve) may be controlled by the BTMS controller 128 or any other suitable control system. In alternative instances, the BTMS unit controller 314 may control valve 302 to allow coolant to flow into cooler 304 when the unit is in the active mode, or into radiator 316 when the unit is in the passive mode. In other cases, other controllers may control valve 302 to control the flow of coolant within the respective BTMS units 204. Regardless of which entity controls valve 302, coolant may be allowed to flow through cooler 304 within a particular BTMS unit 204, or for a predetermined period of time after the BTMS unit 204 will operate in the passive mode. For example, if the refrigerant is still cold and can extract thermal energy from the coolant in coolant line 206, the coolant may flow through cooler 304 even after the refrigerant has not been compressed in compressor 308.

[0051] When flowing through refrigerant line 306, the refrigerant may be of any suitable type, such as R-410A, R-407C, R-134a, R22, Freon, any type of hydrofluorocarbon, any type of chlorofluorocarbon, or virtually any compressible gas or liquid. When the BTMS unit 204 is turned on or in the active mode, the BTMS unit 204 may operate similar to a commercial refrigeration system, where the refrigerant is compressed by compressor 308, undergoes a state change in condenser 310, and the flow rate is regulated by expansion valve 312. At cooler 304, which may also be referred to as an evaporator, thermal energy from the coolant is partially transferred to the refrigerant. In other words, the coolant is cooled at cooler 304. The coolant may include any suitable fluid, such as water, ethylene glycol, oil, surfactant, air, combinations thereof, and so on. The BTMS unit controller 314 for each BTMS unit 204 may control its own BTMS unit 204 and optionally control valve 302. In other words, at least partially based on instructions received from the BTMS controller 128, the BTMS unit controller 314 may control the operation of cooler 304, compressor 308, condenser 310, expansion valve 312, and / or any other elements of its BTMS unit 204.

[0052] In accordance with an example of the present invention, the BTMS controller 128 is configured to selectively turn on and off (e.g., operate in an active mode or a passive mode) individual BTMS cells 204 within the BTMS module 202. The BTMS controller 128 may also track the active usage time of each BTMS cell 204 within each BTMS module 202. The BTMS controller 128 may further track the last time any BTMS cell 204 under its control was actively operated. The BTMS controller 128 may be configured to use data, such as temperature data from the battery 118 and / or its component battery packs 208, 210, along with the active usage data of each of the individual BTMS cells 204, to determine which BTMS cells will regulate the temperature of the battery 118 and / or its component battery packs 208, 210 if any BTMS cell is to operate in the active mode.

[0053] When the BTMS cell 204 operates in the passive mode, coolant may flow through the radiator 316, e.g., via the control valve 302. When operating in the passive mode, the active power-consuming parts of the BTMS cell 204 (e.g., the compressor 308, the condenser 310, etc.) do not need to be operated. Instead, the coolant may dissipate heat energy in the radiator 316. When the temperature of the battery 118 and / or the battery packs 208, 210 is within the desired range, the BTMS cells 204 of the corresponding BTMS module 202 may operate in the passive mode.

[0054] It should be understood that by independently controlling the individual BTMS cells 204 within the BTMS module 202, the BTMS controller 128 is able to control the cooling level. As used herein, cooling refers to extracting one or both of the heat energies from the element to be cooled (e.g., the battery 118, its component battery packs 208, 210, power electronics, hydraulic systems, etc.), or refers to reducing the temperature of the element to be cooled. Thus, depending on the cooling requirements of the battery 118 or the power electronics of the electric machine 100, the BTMS 126 may operate in a manner so as to provide an appropriate level of cooling to the appropriate components of the electric machine 100. As a result, the BTMS 126 may operate in a modular manner to dynamically respond to the cooling demands of the components (e.g., the battery 118) of the electric machine 100.

[0055] Figure 4 is a schematic diagram of an environment 400 of a control system of a battery thermal management system (BTMS) having Figure 2 as depicted in an example of the present invention. As discussed herein, the BTMS controller 128 may receive various signals for its processing to enable the BTMS 126 to operate in a manner that maintains the temperature of the battery 118 and / or the individual battery packs 208, 210 within a controlled temperature range.

[0056] As discussed herein, the BTMS controller 128 may receive signals from the battery controller 120 indicating parameters such as the temperature of the battery 118 and / or the individual battery packs 208, 210 of the battery 118. As discussed herein, in some cases, only one battery controller 120 may report parameters of the battery 118 or even parameters of more than one battery to the BTMS controller 128. In other cases, there may be multiple battery controllers 120, such as dedicated battery controllers 120 for each of the battery packs 208, 210, which report parameters related to the battery 118 or the battery packs 208, 210 to the BTMS controller 128. The reported parameters may be any suitable parameters related to the battery 118 or the battery packs 208, 210, such as the temperature of individual cells of the battery 118 and / or the battery packs 208, 210, the high temperature and / or low temperature of the cells of the battery 118 and / or the battery packs 208, 210, other statistics of the temperature of the cells of the battery 118 and / or the battery packs 208, 210 (such as mean median, standard deviation, etc.), and so on. In some cases, the battery controller 120 or any other suitable controller may also be configured to determine one or more parameters of the coolant for cooling the battery 118 and / or its battery packs 208, 210 and report them to the BTMS controller 128, such as inlet pressure, outlet pressure, inlet temperature, outlet temperature, etc.

[0057] The BTMS controller 128 may also be configured to receive signals from the power electronics controller 402 that provide parameters associated with the power electronics of the electric machine 100. As discussed herein, the BTMS 126 may also be used to cool the power electronics, or indeed any other component of the electric machine 100 in order to operate within a controlled temperature range. Similar to the battery controller 120, the power electronics controller 402 may provide any kind of information to the BTMS controller 128, such as the temperature of the power electronics or its statistical ensemble and / or any kind of temperature and / or pressure data associated with the coolant used to cool the power electronics.

[0058] The BTMS controller 128 may also be configured to receive environmental condition (such as ambient temperature, ambient pressure, etc.) information from the ECM 122 or other controllers. In some instances, this environmental information may also be used to determine whether the individual BTMS cells 204 of a particular BTMS module 202 will operate in an active or passive mode.

[0059] The BTMS controller 128 can receive information (e.g., parameter data) from one or both of the battery controller 120 and / or the power electronics controller 402, and determine whether the BTMS units 204 in one or more of the BTMS modules 202 will operate in an active mode. In some cases, the determination of whether the BTMS units 204 will operate in an active mode can be determined at least in part based on environmental conditions, as received by the BTMS controller 128 from the ECM 122 or other controllers. As discussed in connection with Figure 3 In some cases, a separate BTMS module 202 can correspond to a respective separate battery pack 208, 210. Thus, if a particular battery pack 208, 210 is being cooled due to a high temperature of the battery pack 208, 210, as determined based on a signal received from the battery controller 120, the BTMS controller 128 can cause at least one BTMS unit 204 within the corresponding BTMS module 202 to operate in an active mode. It should be understood that the BTMS controller 128 can command the active operation, or alternatively the passive operation, of a single BTMS module 202, some BTMS modules 202, or all BTMS modules 202 available on the electric machine 100 based on the cooling requirements of the battery 118 and / or other components of the electric machine 100.

[0060] When the BTMS controller 128 determines that a particular BTMS module 202 is to be actively operated, the BTMS controller 128 may further determine how many and / or which of the constituent BTMS units 204 within the BTMS module 202 are to be actively operated. It should be understood that the BTMS controller 128 may make this determination for all of the BTMS modules 202 operating on the electric machine 100 either simultaneously or in a staggered manner. At least in part based on determining which BTMS units 204 are operating in an active mode with each of these BTMS modules 202, the BTMS controller 128 may generate commands and send the commands to different controllers of the electric machine 100. For example, the BTMS controller 128 may determine commands to operate the pumps 216 and send these pump commands to one or more pump controllers 404 configured to operate the pumps 216. Similarly, the BTMS controller 128 may determine commands to operate the valves 302 and send these valve commands to one or more valve controllers 406 configured to operate the valves 302. Note that in some cases, the valve 302 may be controlled by the BTMS controller 314. Additionally, the BTMS controller 128 may determine commands to control the individual BTMS units 204 and send these BTMS unit commands to the corresponding BTMS unit controllers 314. It should be understood that there may be other components and / or other controllers that may be directed by the BTMS controller 128 when operating the BTMS 126 in a dynamic and modular mechanism as disclosed herein.

[0061] In some embodiments, the BTMS controller 128 and any of the other controllers discussed herein may include an electronic control module, a central processing unit (CPU), a graphics processing unit (GPU), both a CPU and a GPU, a microprocessor, a digital signal processor, or other processing units or components known in the art. Alternatively, or additionally, the functions described herein may be performed at least in part by one or more hardware logic components. For example, but not limited to, illustrative types of hardware logic components that may be used include field programmable gate arrays (FPGAs), application specific integrated circuits (ASICs), application specific standard products (ASSPs), system on a chip systems (SOCs), complex programmable logic devices (CPLDs), and the like. Additionally, the BTMS controller 128 may have its own local memory, which may also store program modules, program data, and / or one or more operating systems. For example, the memory / storage device may store battery thermal management control software to implement the methods disclosed herein. The BTMS controller 128 may include one or more cores.

[0062] In some cases, communication between the BTMS controller 128 and various other components and / or controllers of the electric machine 100 can be via any suitable protocol-based communication or any suitable non-protocol-based communication. In an example of the present invention, the BTMS controller 128 can have a wired communication connection to different components of the electric machine 100 with which it communicates. In other cases, the BTMS controller 128 can have a wireless communication connection to various components of the electric machine 100 with which it communicates (e.g., Bluetooth, WiFi, Direct WiFi (without using a wireless router), etc.). In additional cases, the BTMS controller 128 can have a hybrid of wired and wireless communication links to the various components of the electric machine 100 with which it communicates. Regardless of the exact nature of its communication link, the BTMS controller 128 is configured to receive various information about the components it is to cool (e.g., battery packs 208, 210), and based on that information and any other data, determine which of the BTMS modules 202 and constituent BTMS cells 204 (if any) are to be operated.

[0063] In additional examples, the BTMS controller 128 is configured to track the use of each BTMS cell 204 in the active mode. The BTMS controller 128 can determine which BTMS cells 204 are actively operating within the respective BTMS modules 202 at least in part based on the total active operation time of the respective BTMS cells 204. For example, when a BTMS cell 204 within a BTMS module 202 is to be actively operated, the BTMS controller 128 can cause those BTMS cells 204 having the least active operation time to be operated. This can increase the overall lifespan of the BTMS 126 and / or the constituent BTMS modules 202 and / or BTMS cells 204.

[0064] In some cases, the BTMS controller 128 is configured to track when each BTMS cell 204 within any BTMS module 202 of the BTMS 126 was last used in the active mode. In some instances, the BTMS controller 128 may operate the BTMS cell 204 at least in part based on the time when the particular BTMS cell 204 last operated in the active mode. The BTMS cell 204 may have a latency period during which it is not efficient or not desirable to actively operate the BTMS cell 204. Thus, in some cases, when additional BTMS cells 204 are needed for active operation, the BTMS controller 128 may select a BTMS cell 204 that has not recently been actively operated. In other words, the BTMS controller 128 may not instruct the operation of any BTMS cell 204 within the latency interval after its last effective use. In some cases, the latency period may be a time period in the range of about 15 seconds to about 6 minutes. For example, in some cases, the latency period may be about 2 minutes from the last active use of the BTMS cell. The foregoing ranges are merely examples, and it should be understood that the latency period of the BTMS cell 204 may be any suitable value.

[0065] It should be understood that the control mechanism as shown in the environment 400 may allow for modular and on-demand operation of the BTMS 126. Only the BTMS modules 202 corresponding to the elements to be cooled may be operated. Additionally, only the BTMS cells 204 within the operating BTMS modules 202 are actively operated. In this way, cooling is provided only where it is needed, without providing cooling to components that do not require cooling. Further, the cooling level is adjusted according to the cooling needs. This provides better control of the cooling requirements in a robust and dynamic manner.

[0066] Figure 5 is an example method 500 for a battery thermal management system (BTMS) 126 for providing Figure 2 The process of the method 500 may be performed by any suitable manufacturer of the BTMS 126, system integrator, manufacturer of the electric machine 100, other third-party original equipment manufacturers (OEMs), combinations thereof, and the like.

[0067] At block 502, one or more battery thermal management system (BTMS) modules 202 are provided, where each of the BTMS modules 202 corresponds to battery packs 208, 210 of battery 118. As discussed herein, the BTMS modules 202 of the BTMS 126 can operate independently. For example, a particular BTMS module 202 can operate when its corresponding element to be cooled (e.g., battery packs 208, 210, power electronics, etc.) is to be cooled. As further discussed herein, the individual BTMS modules 202 can operate independently, e.g., under the control of the BTMS controller 128. The BTMS module 202 can operate at least in part based on measurements (e.g., temperature measurements, etc.) of the element to be cooled by each BTMS module 202.

[0068] At block 504, a coolant path to its corresponding battery packs 208, 210 is provided for each BTMS module 202. The coolant path can be the coolant line 206, as discussed herein. The coolant path can also include a heat exchanger 212, as discussed herein. Generally, the coolant path can include any suitable elements through which the coolant can flow, e.g., in a cycle where the coolant is cooled at the BTMS module 202 and then used to cool the battery packs 208, 210 or other elements to be cooled. The coolant line 206 and / or the heat exchanger can be constructed of any suitable material, such as stainless steel, steel, aluminum, polytetrafluoroethylene (PTFE), or any other suitable material.

[0069] At block 506, one or more pumps 216 can be provided to pump coolant to each of the BTMS modules 202. In some cases, a single pump 216 can be provided for each BTMS module 202. In other cases, more than one pump 216 can be provided for each BTMS module 202. In additional cases, two or more BTMS modules can share a single pump 216. Regardless of the configuration of the pumps 216 to the BTMS modules 202, the pumps 216 can be controlled, e.g., by the BTMS controller 128 in conjunction with a local controller, to pump coolant through the coolant line 206 to the BTMS module 202. In some cases, the pump 216 can be upstream of its corresponding BTMS module 202. In other cases, the pump 216 can be downstream of its corresponding BTMS module 202. In either case, pumping of the coolant within the coolant line 206 causes the coolant to pass through the respective BTMS module 202 and / or any operative BTMS unit 204 within the BTMS module 202. In some cases, the pump 216 can be configured to pump coolant stored in the coolant tank 214, which can serve as a coolant reservoir or sump.

[0070] At block 508, multiple independently operable BTMS units 204 can be provided within each of one or more BTMS modules 202. Independently operable means that some of the BTMS units 204 can operate in an active mode, where coolant is cooled through a refrigeration process, while other BTMS units 204 can operate passively, where coolant flows through the radiator 316 of the BTMS unit 204. As discussed herein, the BTMS units 204 within a BTMS module 202 can be arranged in parallel such that coolant flows through all of the BTMS units 204 within the BTMS module 202. When the BTMS units 204 within a BTMS module 202 are not actively working, the coolant within the BTMS units 204 can be directed to the radiator 316 rather than the cooler 304, for example, by operation of the valve 302. The operation of individual BTMS units 204 can be controlled by the BTMS controller 128, for example, at least in part based on parameters (such as temperature) of the element to be cooled. For example, if a certain level of cooling is required, a single BTMS unit 204 can operate actively within a BTMS module 202 having four BTMS units 204. If a higher level of cooling is required, two BTMS units 204 of the same BTMS module 202 can be operated actively.

[0071] It should be noted that some operations of method 500 may not be performed in the order presented, with additional elements, and / or without some elements. Some operations of method 500 may also occur substantially simultaneously and can thus end in an order different from the order of operations shown above.

[0072] It should be understood that the process of method 500 enables the deployment of the BTMS 126 as disclosed herein on the electric machine 100. The BTMS 126 can operate in a modular manner to provide an appropriate level of on-demand cooling. Thus, the cooling requirements of components such as the battery packs 208, 210 of the electric machine 100 can be met in a dynamic and on-demand manner. As disclosed herein, the BTMS 126 results in battery life due to better delivery of the thermal management needs of the battery 118 and thus reduces the cost of operating the electric machine 100.

[0073] Figure 6 is a flowchart of an example method 600 for operating Figure 2 a battery thermal management system (BTMS). The process of method 600 can be performed by the BTMS controller 128 alone or in combination with one or more other components of the electric machine 100. It should also be noted that the process of method 600 can be performed when the electric machine 100 is running (e.g., performing a task), charging, idling, shut down, or any combination thereof.

[0074] At block 602, the BTMS controller 128 can receive an indication of the temperature of battery packs 208, 210 from the battery controller 120. The indication of temperature can be of any suitable type. For example, in some cases, the temperature of a representative battery of battery packs 208, 210 can be received. In other cases, the BTMS controller 128 can receive the average, median, variance, standard deviation, minimum, maximum, or indeed any suitable descriptive statistic of the temperatures of multiple individual batteries of battery packs 208, 210.

[0075] At block 604, the BTMS controller 128 identifies the BTMS module 202 associated with the battery packs 208, 210 for which the temperature indication was received. As disclosed herein, individual battery packs 208, 210 of the electric machine 100 to be cooled, or indeed any individual component, can have a corresponding BTMS module 202 that can be operated modularly independent of other BTMS modules 202 of the electric machine 100. Thus, when a particular temperature level is received and / or determined by the BTMS controller 128, the BTMS controller 128 can identify the corresponding BTMS module 202 for battery packs 208, 210.

[0076] At block 606, the BTM controller 128 can determine whether the temperature indicated for battery packs 208, 210 is greater than a corresponding threshold. If the temperature is not greater than the corresponding threshold, the method 600 can return to block 602, where the BTMS controller 128 can continue to receive the temperature indication of battery packs 208, 210. For example, the threshold can be the upper limit of the temperature range to which the battery packs 208, 210 are to be controlled. For example, if a particular battery pack 208, 210 is to be within a range of 10°C and 20°C, the threshold can be set at the upper end of that range, or 20°C. In other cases, the threshold can be set at the midpoint of the allowable temperature range. In this case, referring to the previous control range, the threshold can be set at 15°C. In other cases, the threshold level can be set at a lesser amount below the top of the range. Again, referring to the previous example temperature range, the threshold level can be set at 18°C. The range (10°C to 20°C) is merely an example, and the temperature control range of battery packs 208, 210 can be any suitable range. In some cases, the control range of the battery temperature can be from about 10°C to about 40°C. In other cases, the control range of the temperature can be within the range of about 15°C to about 30°C. In other instances, the temperature control range can be within the range of about 10°C to 25°C.

[0077] If, at block 606, the BTMS controller 128 determines that the temperature associated with battery packs 208, 210 received as part of the process at block 608 is greater than a corresponding threshold, then the BTMS controller 128 can determine that one or more BTMS cells 204 within the BTMS module 202 are to be activated, at least in part, based on that temperature. The BTMS controller 128 can determine how many and / or which of the BTMS cells 204 of the BTMS module 202 are to be actively operated based on various parameters. For example, the total number of BTMS cells 204 to be operated can be determined based on how high the temperature received as part of the process at block 602 is compared to the desired temperature range of the battery packs 208, 210. In some cases, the BTMS controller 128 can compare the temperature associated with the battery packs 208, 210 to multiple threshold levels to determine how many of the BTMS cells 204 within the BTMS module 202 are to be actively operated. Regarding which BTMS cells 204 are to be actively operated, the BTMS controller 128 can keep track of the overall usage of each individual BTMS cell 204 and actively operate the BTMS cell 204 with the lowest active operation time with preference. In some cases, when a BTMS cell 204 cannot be actively operated or otherwise operated as desired, the BTMS cell 204 can have a waiting time after active operation. Thus, in these cases, the BTMS controller 128 can select the BTMS cell 204 that has not been operated most recently (e.g., within a threshold time period) for operation. In some cases, determining how many and / or which of the BTMS cells 204 are operating in the active mode can take into account environmental conditions (e.g., ambient temperature). For example, if the ambient temperature is below the desired operating range of the battery packs 208, 210 and the battery packs 208, 210 are to be cooled, a passive mode, rather than an active mode, can be used to cool the battery packs 208, 210.

[0078] At block 610, the BTMS controller 128 may cause one or more BTMS cells 204 within the BTMS module 202 to activate. Activating the BTMS cells 204 to operate actively may require coordinating the various functions of various components. For example, the BTMS module 128 may instruct the respective BTMS cell controllers 314 of the BTMS cells 204 of the active operation of the BTMS cells 204. Additionally, in some cases, the BTMS controller 128 may control the valve 302 such that coolant can flow into the active components of the BTMS cells 204 to be actively operated. Further, the BTMS controller 128 may control the pump speed of the pump 216 corresponding to the BTMS module 202 to be operated. In some cases, the pump speed or velocity of the pump 216 may be determined at least in part based on the number of BTMS cells 204 actively operating within the BTMS module 202 and / or the cooling requirements of the corresponding battery packs 208, 210. For example, more BTMS cells 204 operating with the BTMS module 202 may cause the BTMS controller 128 to operate the corresponding pump 216 by a greater margin.

[0079] It should be noted that some operations of the method 600 may not be performed in the order presented, have additional elements, and / or not have some elements. Some operations of the method 600 may also occur substantially simultaneously and may thus end in an order different from the order of operations shown above.

[0080] Computer-executable program instructions may be loaded onto a general-purpose computer, a special-purpose computer, a processor, or other programmable data processing apparatus to produce a particular machine such that the instructions executed on the computer, processor, or other programmable data processing apparatus create means for implementing one or more functions specified in one flowchart block or a plurality of flowchart blocks. These computer program instructions may also be stored in a computer-readable memory that may direct a computer or other programmable data processing apparatus to operate in a particular manner such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means for implementing one or more functions specified in one or more blocks of the flowchart. In one instance, the present invention may provide a computer program product that includes a computer-usable medium having computer-readable program code or program instructions contained therein, the computer-readable program code being adapted to be executed to implement one or more functions specified in one or more blocks of the flowchart. The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus such that a series of operational elements or steps are executed on the computer or other programmable apparatus to produce a computer-implemented process such that the instructions executed on the computer or other programmable apparatus provide elements or steps for implementing the functions specified in one or more blocks of the flowchart.

[0081] It will be appreciated that each of the memories and data storage devices described herein may store data and information for subsequent retrieval. The memories and databases may communicate with each other and / or with other databases, such as a centralized database or other types of data storage devices. When needed, the data or information stored in the memory or database may be transferred to a centralized database capable of receiving data, information, or data records from more than one database or other data storage devices. In other cases, the databases shown may be integrated or distributed into any number of databases or other data storage devices.

[0082] Industrial Applicability

[0083] The present invention describes systems and methods for improving, modularizing, and cooling on demand multiple components of an electric machine 100, such as a battery 118, its battery packs 208, 210, and / or power electronics. These electric machines 100 offer several advantages, such as reduced carbon, particulate, and / or VOC emissions, and high torque at low revolutions per minute (RPM). However, the electric machine 100 uses a battery 118 that requires temperature control. In some cases, the battery 118 used in the electric machine 100 may be expensive, and thus it is desirable to maximize the operating life of these batteries by carefully controlling their operating conditions, including the operating temperature. Accordingly, the techniques disclosed herein enable the widespread use of more environmentally friendly and mechanically advantageous electric machines 100 while reducing the ownership and use costs of such electric machines 100 by maximizing the operating life of the batteries 118 of these electric machines 100.

[0084] As disclosed herein, a battery thermal management system (BTMS) 126 may be used in a modular fashion with variable levels of cooling intensity. Additionally, the cooling intensity may be increased or decreased in a dynamic and on-demand manner. As a result, the temperature of the battery 118 or other components of the electric machine 100 may be continuously monitored and controlled in a robust manner. Accordingly, the temperature of the battery packs 208, 210 may be controlled within a more stringent range and there is no or less deviation outside of this more stringent range compared to prior thermal technologies. Additionally, the electric machine 100 may have a more dynamic power draw from the battery compared to other applications, such as electric vehicles. As disclosed herein, the BTMS 126 enables the regulation of the temperature of the battery packs 208, 210 even when the electric machine 100 has greater demands compared to other applications of the battery pack 118. Accordingly, the techniques and methods discussed herein enable the electrification of a wider range of electric work and mobility solutions.

[0085] The BTMS126 itself is an improved design over prior thermal systems because the BTMS126 provides variable cooling levels in a manner such that subcomponents, such as each of the BTMS modules 202 and / or the BTMS cells 204, are not overburdened. By operating the BTMS cells 204 only when needed, the BTMS126 disclosed herein can have a longer operating life than other thermal solutions. Additionally, by controlling the operation of the BTMS cells 204 in a manner that levels out the operating time, the entire BTMS126 can have a relatively high operating level between maintenance intervals.

[0086] Although the systems and methods of the electric machine 100 are discussed in the context of mining trucks and other mining machines, it should be understood that the systems and methods discussed herein can be applied to a wide variety of machines and vehicles across a wide variety of industries, such as construction, mining, farming, transportation, military, combinations thereof, etc. For example, the BTMS126 and temperature control mechanisms disclosed herein can be applied to a compactor in the paving industry or a harvester in the agricultural industry.

[0087] While aspects of the present invention have been specifically shown and described with reference to the above examples, those skilled in the art will understand that various additional examples can be envisioned by modifying the disclosed machines, systems, and methods without departing from the spirit and scope of the disclosed subject matter. These examples are to be understood as falling within the scope of the present invention as determined based on the claims and any equivalents thereof.

[0088] Unless otherwise indicated herein, the recitation of numerical ranges herein is merely intended to be a shorthand method of referring individually to each separate value falling within the range, and each separate value is incorporated into the specification as if it were recited individually herein. All methods described herein can be performed in any suitable order, unless otherwise indicated herein.

Claims

1. A machine (100), comprising: an engine (114) for propelling the machine (100); a battery (118) configured to supply power to the engine (114); a battery controller (120) configured to report a temperature associated with the battery (118); and a battery thermal management system (BTMS) (126) comprising: a coolant line (206) configured to circulate coolant to cool the battery (118); a BTMS module (202) having a first BTMS unit (204) and a second BTMS unit (204), wherein the first BTMS unit (204) and the second BTMS unit (204) are capable of operating independently, and wherein the BTMS module (202) is configured to provide coolant cooled by the first BTMS unit (204) and the second BTMS unit (204) to cool the battery (118); and a BTMS controller (128) configured to receive a temperature level associated with the battery (118) and independently operate the first BTMS unit (204) and the second BTMS unit (204).

2. The machine (100) according to claim 1, wherein the battery (118) includes a first battery pack (208, 210) and a second battery pack (208, 210), and wherein the BTMS module (202) is configured to cool the first battery pack (208, 210).

3. The machine (100) according to claim 2, wherein the BTMS (126) further comprises: a second BTMS module (202) configured to cool the second battery pack (208, 210), wherein the second BTMS module (202) includes a third BTMS unit (204) and a fourth BTMS unit (204), and wherein the third BTMS unit (204) and the fourth BTMS unit (204) are capable of operating independently.

4. The machine (100) according to claim 1, wherein it further comprises power electronics, and wherein the BTMS (126) is further configured to cool the power electronics.

5. The machine (100) according to claim 1, wherein the first BTMS unit (204) further comprises: a valve (302) for controlling the flow of coolant into one of a cooler (304) or a radiator (316).

6. The machine (100) according to claim 1, wherein the BTMS (126) further comprises: a first pump (216) for pumping coolant through the BTMS module (202).

7. A method of cooling a battery (118), comprising: Coolant is circulated from a first battery pack (208, 210) to a first battery thermal management system (BTMS) module (202) configured to cool the coolant via a coolant line (206) and using a first pump (216), wherein the first BTMS module (202) includes a first BTMS unit (204) and a second BTMS unit (204); Determine that the first BTMS unit (204) will operate actively to cool the first battery pack (208, 210); Cause the first BTMS unit (204) to operate actively; Circulate the coolant from a second battery pack (208, 210) to a second BTMS module (202) configured to cool the coolant via the coolant line (206) and using a second pump (216), wherein the second BTMS module (202) includes a third BTMS unit (204) and a fourth BTMS unit (204); Determine that the third BTMS unit (204) will operate actively to cool the first battery pack (204); and Cause the third BTMS unit (204) to operate actively.

8. The method according to claim 7, further comprising: Controlling a first valve (302) to allow the coolant to enter a cooler (304) associated with the first BTMS unit (204).

9. The method according to claim 7, wherein, The determining that the first BTMS unit (204) will operate actively to cool the first battery pack (208, 210) further includes: Receiving, by a BTMS controller (128), a temperature level associated with the first battery pack (208, 210); Determining that the temperature level of the first battery pack (208, 210) is greater than a threshold level; and Determining, by the BTMS controller (128) and at least in part based on the temperature level greater than the threshold level, that at least one of the first BTMS unit (204) or the second BTMS unit (204) is to operate actively.

10. The method according to claim 7, further comprising: Receiving, by a BTMS controller (128), a temperature level associated with the second battery pack (208); Determining that the temperature level of the second battery pack is lower than a threshold level; Determining, by the BTMS controller (126) and at least in part based on the temperature level lower than the threshold level, that the third BTMS unit (204) is to operate passively; and Causing the third BTMS unit (204) to operate passively, wherein the coolant flows through a radiator (316) associated with the third BTMS unit (204).

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