Wide-temperature-range self-adaptive energy storage battery thermal management system and control method

Abstract

The application discloses a wide-temperature-range self-adaptive energy storage battery thermal management system and a control method. The system comprises a controller, a liquid circulation subsystem and an air circulation subsystem, and adopts an integrated cross-flow diagonal structure in physical architecture. The liquid circulation subsystem comprises S-shaped reciprocating arranged cooling pipelines extending and returning along a first direction; the air circulation subsystem flow channel extends along a diagonal second direction, is non-parallel and obliquely intersects with the first direction, and the air inlet hole and the back pressure valve are diagonally distributed on different bulkheads and are communicated with external cold and hot air machines. The controller dynamically adjusts the running state of the liquid and air circulation subsystems based on thermal state parameters. The application can cover high and low temperature scenes, has condensation prevention and micro-positive pressure protection capabilities, and significantly improves the temperature uniformity and safety of the energy storage system through adaptive adjustment of air and liquid cooperation.

Description

Technical Field

[0001] This invention belongs to the field of new energy storage battery technology, specifically relating to a wide-temperature-range, adaptive energy storage battery thermal management system and control method. Background Technology

[0002] With the advancement of the global energy transition, electrochemical energy storage systems have become core equipment in power systems, communication base stations, and new energy ships due to their advantages such as fast adjustment speed and flexible deployment. As the energy carrier of the system, the performance, lifespan, and safety of energy storage batteries are highly dependent on the operating temperature. Typically, the ideal operating temperature range for lithium-ion batteries is 20℃~40℃, and the temperature difference between the cells within the battery cluster needs to be strictly controlled.

[0003] However, in applications involving large-capacity, high-energy-density sealed energy storage chambers, existing thermal management technologies face multiple severe challenges:

[0004] First, a single thermal management mode struggles to balance a wide temperature range with low energy consumption. Traditional air-cooled systems are simple in structure, but their low heat transfer coefficient under high-temperature or high-rate charge-discharge conditions makes it difficult to meet the heat dissipation requirements of high heat generation, easily leading to battery thermal runaway. In contrast, while liquid-cooled systems have high heat transfer efficiency, forcing the high-power chiller to operate under mild conditions with low battery heat generation or low ambient temperature not only results in significant energy waste, but frequent start-stop cycles also shorten equipment lifespan. Furthermore, most existing liquid-cooled systems focus on cooling and have weak active heating capabilities under extremely cold conditions, making it difficult to address the issues of increased electrolyte viscosity and battery activity degradation at low temperatures.

[0005] Secondly, there is a conflict between the condensation risk of the liquid cooling system and the protection of the sealed chamber. Inside the energy storage chamber, the surface temperature of the liquid cooling pipes is often much lower than the ambient temperature. When the humidity inside the chamber is high, condensation is very likely to occur on the pipe walls, and the dripping condensate may cause short circuits in the battery modules or even fires. Existing technologies often lack real-time closed-loop control for dew point temperature, making it difficult to eliminate the condensation risk at its physical source. At the same time, although the energy storage chamber is a sealed structure, it still needs to exchange gases with the outside (such as depressurization or ventilation). When introducing outside air, if there is a lack of effective pressure management and humidity pretreatment mechanisms, external moisture, dust, and salt spray can easily penetrate into the chamber through uncontrolled paths, corroding electrical components and reducing the system's insulation performance.

[0006] Third, the flow field layout and temperature uniformity of the thermal management system need to be optimized. In existing energy storage battery compartment designs, the flow channel layout of the cooling medium is often relatively simple. For example, a simple unidirectional flow design can easily lead to excessive temperature differences between the inlet and outlet of the battery cluster, forming a significant temperature gradient. How to achieve three-dimensional cross-coverage of the cooling medium within a limited compartment space through innovation in physical architecture, so as to eliminate thermal dead zones and disrupt the thermal boundary layer, is a key challenge in improving heat exchange efficiency.

[0007] Fourth, the control strategy is rigid and lacks fault tolerance mechanisms. Traditional thermal management systems mostly adopt simple start-stop control based on a single temperature threshold, lacking intelligent perception and adaptive adjustment of ambient temperature and humidity and load change trends, resulting in large temperature fluctuations. More seriously, existing systems usually rely on a single cooling loop. Once the water pump fails or the fan is blocked, the entire thermal management system will completely fail, posing a great threat to the safe operation of the energy storage system. Summary of the Invention

[0008] The purpose of this invention is to address the shortcomings of the aforementioned background technology and provide a wide-temperature-range, adaptive energy storage battery thermal management system and control method that can cover all high and low temperature scenarios, has anti-condensation and micro-positive pressure protection capabilities, and can adaptively adjust the air-liquid coordinated operation according to the operating conditions.

[0009] The technical solution adopted in this invention is: a wide temperature range, adaptive energy storage battery thermal management system, comprising: a controller, a liquid circulation subsystem, and an air circulation subsystem;

[0010] The controller is used to dynamically adjust the operating status of the liquid circulation subsystem and the air circulation subsystem based on the monitored thermal state parameters;

[0011] The liquid circulation subsystem and the air circulation subsystem adopt an integrated cross-flow diagonal structure in their physical architecture, forming a composite three-dimensional cross-heat exchange network covering the entire battery cluster, wherein:

[0012] The liquid circulation subsystem includes cooling pipes arranged along the top and bottom planes of the battery compartment. The cooling pipes are arranged in an S-shaped reciprocating pattern extending and turning back along a first direction. The cooling water inlet and cooling water outlet are respectively arranged on two compartment walls opposite each other along the first direction of the battery compartment.

[0013] The air circulation subsystem has its flow channel extending along a second direction of the battery compartment. This second direction is the diagonal direction connecting the air inlet and the back pressure valve, and is spatially non-parallel to the first direction, forming a three-dimensional oblique relationship. The air inlet and the back pressure valve are respectively arranged on two other opposing compartment walls that are different from the compartment walls where the cooling water inlet and the cooling water outlet are located, and the two are spatially diagonally distributed. The air inlet is connected to an external hot and cold air fan that integrates a drying and heating module.

[0014] In the above technical solution, the height of the cooling water inlet hole in the vertical direction is lower than the height of the cooling water outlet hole; the cooling pipe is configured to form a fluid channel that facilitates gas discharge by utilizing the height difference.

[0015] In the above technical solution, the back pressure valve is configured to have a preset opening pressure threshold, so that when the air circulation subsystem is running, in conjunction with the air intake pressurization effect of the external hot and cold air blower, a slightly positive pressure state higher than the external environmental pressure is maintained in the battery compartment, thereby preventing external moisture and particulate pollutants from penetrating into the battery compartment through uncontrolled paths.

[0016] In the above technical solution, the system integrates a distributed sensor group, which is communicatively connected to the controller; the sensor group includes at least:

[0017] A temperature sensor array is attached to the surface of the battery cluster and its distribution covers the corresponding positions of the battery cluster at the cooling water inlet, outlet, central area and edge area, for real-time monitoring of the overall temperature distribution of the battery cluster.

[0018] The temperature and humidity monitoring unit is deployed inside and outside the battery compartment and is configured to collect temperature and relative humidity data inside and outside the battery compartment in real time.

[0019] In the above technical solution, the control method of the system includes: acquiring real-time temperature data at various distribution locations of the battery cluster through the temperature sensor array, and calculating the real-time average temperature of the battery cluster by the controller; the method presets a heating threshold, a first cooling threshold, and a second cooling threshold, wherein the heating threshold is less than the first cooling threshold, and the first cooling threshold is less than the second cooling threshold; the controller performs the start-up, shutdown, and adjustment of the fluid medium according to the following logic based on the comparison result between the average temperature of the battery cluster and the above thresholds:

[0020] When the average temperature of the battery cluster is lower than the heating threshold, the controller instructs the air circulation subsystem to output hot air;

[0021] When the average temperature of the battery cluster is between the first cooling threshold and the second cooling threshold, the controller only instructs the air circulation subsystem to output cold air;

[0022] When the average temperature of the battery cluster is higher than the second cooling threshold, the controller instructs the air circulation subsystem to output cold air and instructs the liquid circulation subsystem to activate the liquid cooling function for coordinated operation.

[0023] In the above technical solution, when the average temperature of the battery cluster is lower than the heating threshold, the controller continuously calculates the deviation signal between the real-time average temperature of the battery cluster and the target set temperature; the controller dynamically adjusts the output wind speed and wind pressure of the air circulation subsystem according to the current amplitude, the cumulative amount over time and the rate of change of the deviation signal, until the average temperature of the battery cluster gradually converges to the target set temperature.

[0024] In the above technical solution, when the average temperature of the battery cluster is between the heating threshold and the second cooling threshold, the controller adjusts the fan speed of the air circulation subsystem and uses the flow resistance characteristics of the back pressure valve to control the residence time of the introduced external cold air in the battery compartment; by optimizing the residence time, it is ensured that the air medium fully absorbs the battery heat before being discharged from the compartment, thereby maintaining a stable battery temperature without having to start the liquid circulation subsystem.

[0025] In the above technical solution, when the average temperature of the battery cluster is higher than the second cooling threshold, the controller instructs the liquid circulation subsystem and the air circulation subsystem to operate simultaneously with preset strong cooling operating parameters; by utilizing the synergistic effect of air flow field and liquid cooling, a compound turbulence effect is generated on the battery surface and heat exchange interface, thereby physically destroying or significantly thinning the thermal boundary layer and maximizing the convective heat transfer coefficient.

[0026] In the above technical solution, when the relative humidity outside the cabin detected by the sensor group is higher than the preset safe inhalation threshold, the controller forcibly activates the drying function integrated by the hot and cold air blower to pre-treat the inhaled external air by dehumidification.

[0027] Meanwhile, the controller calculates the dew point temperature in the cabin in real time by combining the relative humidity data and temperature data inside the cabin. When the dew point temperature inside the cabin is close to or higher than the real-time temperature of the battery cluster in the cooling water inlet area collected by the temperature sensor array, the controller instructs the air circulation subsystem to inject dehumidified pre-treated air into the cabin to replace the original gas in the cabin until the humidity parameter inside the cabin is reduced to below the safe threshold for eliminating the risk of condensation.

[0028] In the above technical solution, the controller uses flow rate and pressure sensors deployed in the sensor group to monitor the actual wind pressure and actual water pressure of the air circulation subsystem and the liquid circulation subsystem in real time. The controller uses the target wind pressure and target water pressure calculated based on the difference between the real-time average temperature of the battery cluster and the target set temperature as control commands to drive the corresponding subsystem to operate. The controller performs a closed-loop comparison between the monitored actual wind pressure and actual water pressure and the target wind pressure and target water pressure in real time. When the deviation between the actual value and the target value continues to exceed the preset safety threshold, the controller determines that there is a blockage or leakage fault in the corresponding subsystem and triggers the fault protection logic, enabling the fault-free subsystem to operate in compensation or issuing an alarm to achieve fault-tolerant control of the system.

[0029] The beneficial effects of this invention are:

[0030] Firstly, at the physical architecture level, this invention innovatively constructs a composite three-dimensional cross-heat exchange network with an integrated cross-flow diagonal structure. By designing the liquid circulation subsystem as an S-shaped reciprocating arrangement extending and folding along the first direction, and forming a non-parallel three-dimensional oblique relationship with the air circulation subsystem extending along the second diagonal direction, this system completely breaks through the thermal dead zone limitations easily generated by traditional single-channel layouts. This dual-working-fluid, full-domain coverage physical architecture not only maximizes the utilization rate of the limited space inside the cabin, but also achieves balanced thermal management of the battery cluster's center and edge regions through the physical intersection of the gas and liquid paths, significantly improving the system's temperature uniformity and enabling it to easily cope with the wide temperature range requirements of all scenarios, from extreme cold heating to high temperature cooling.

[0031] Secondly, in terms of structural details and protective design, this system achieves passive optimization and active defense in fluid transport. For the complex S-shaped liquid cooling pipeline, this invention utilizes a low-inlet, high-outlet geometric layout, combined with fluid dynamic pressure and buoyancy effects, to form an ascending flow channel capable of automatic, step-by-step exhaust. This effectively prevents air resistance and localized overheating caused by air accumulation in the pipeline, improving the circulation stability of the liquid cooling circuit. Simultaneously, a back pressure valve is introduced into the air-cooled circuit to work with the intake pressurization, establishing and maintaining a slightly positive pressure environment within the chamber. While conducting air heat exchange, this continuously and actively resists the infiltration of external atmospheric elements, effectively preventing external moisture, salt spray, and particulate pollutants from entering the chamber through uncontrolled paths, significantly improving the insulation safety and corrosion resistance of the energy storage system.

[0032] Furthermore, at the control strategy level, this invention achieves adaptive adjustment based on optimal energy efficiency and ultimate heat transfer. This method abandons the traditional rigid single control mode, dividing the operating conditions into three logical zones by pre-setting dual temperature thresholds, thus achieving on-demand energy supply: in the low-temperature zone, PID algorithms are used to precisely control wind speed and pressure for rapid preheating; in the medium-temperature zone, only air cooling is used, and residence time is optimized for low-energy cooling, avoiding ineffective start-stop of the liquid-cooled unit; in the high-temperature zone, the gas-liquid dual-channel operation is employed, utilizing the superposition of high-velocity air and liquid to physically disrupt the thermal boundary layer on the battery surface, generating a compound turbulence effect, thereby maximizing the convective heat transfer coefficient and effectively suppressing the risk of battery thermal runaway.

[0033] Finally, regarding system safety and intelligent fault tolerance, this invention constructs a multi-dimensional closed-loop protection mechanism. Relying on a distributed sensor array, the system possesses deep environmental perception capabilities. Addressing the critical condensation hazard of liquid cooling systems, this invention no longer relies on fuzzy estimations but instead compares the dew point temperature inside the chamber with the temperature of the battery's water inlet area (coldest point), forcibly intervening in drying and gas replacement before the risk occurs, eliminating short-circuit risks at their physical source. Simultaneously, the system introduces a health self-check logic based on flow resistance monitoring. By comparing the target pressure calculated by the closed-loop control algorithm with the actual pressure fed back by the sensors, it can identify pipeline blockages or leaks in milliseconds and automatically activate fault-free subsystems for compensatory operation. This dual-system hot backup fault-tolerant design significantly improves the operational reliability of the energy storage power station throughout its entire lifecycle, solving the industry pain point that a single system failure can lead to total system failure. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the structure of the present invention;

[0035] Figure 2 This is a schematic diagram of the overall control logic of the present invention;

[0036] Figure 3 This is a schematic diagram of the control logic under the heating mode of the present invention;

[0037] Figure 4 This is a schematic diagram of the control logic under the mild cooling mode of the present invention;

[0038] Figure 5 This is a schematic diagram of the control logic under the strong cooling mode of the present invention;

[0039] Figure 6 The measured results show the cooling rate of the battery in the flat rectangular energy storage sealed chamber of the battery pack of this invention.

[0040] Among them, 1-hull, 2-left bulkhead, 3-cooling water inlet, 4-cooling water inlet pipe, 5-forward bulkhead, 6-electrical input connector, 7-sensor group communication interface, 8-electrical output connector, 9-flange, 10-back pressure valve, 11-right bulkhead, 12-cooling water outlet pipe, 13-cooling water outlet, 14-cooling pipeline, 15-rear bulkhead, 16-air inlet. Detailed Implementation

[0041] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments to facilitate a clear understanding of the present invention, but these descriptions do not constitute a limitation on the present invention.

[0042] like Figure 1 As shown, the present invention provides a wide temperature range, adaptive energy storage battery thermal management system, including: a controller, a liquid circulation subsystem, and an air circulation subsystem;

[0043] The controller is used to dynamically adjust the operating status of the liquid circulation subsystem and the air circulation subsystem based on the monitored thermal state parameters;

[0044] The liquid circulation subsystem and the air circulation subsystem adopt an integrated cross-flow diagonal structure in their physical architecture, forming a composite three-dimensional cross-heat exchange network covering the entire battery cluster, wherein:

[0045] The liquid circulation subsystem includes cooling pipes 14 arranged along the top and bottom planes of the battery compartment 1, located on the upper and lower sides of the battery body. The cooling pipes 14 are arranged in an S-shaped reciprocating arrangement extending and turning back along the first direction. The cooling water inlet 3 and cooling water outlet 13 are respectively arranged on two compartment walls of the battery compartment 1 opposite to each other along the first direction.

[0046] The air circulation subsystem has its flow channel extending along the second direction of the battery compartment 1. The second direction is the diagonal direction connecting the air inlet 16 and the back pressure valve 10, and is spatially non-parallel to the first direction, forming a three-dimensional oblique relationship. The air inlet 16 and the back pressure valve 10 are respectively arranged on two other opposing compartment walls that are different from the compartment walls where the cooling water inlet 3 and the cooling water outlet 13 are located, and the two are spatially diagonally distributed. The air inlet 16 is connected to an external hot and cold air fan that integrates a drying and heating module.

[0047] This system employs a hybrid architecture that deeply integrates liquid cooling and air cooling. Physically, a three-dimensional cross-heat exchange network is constructed through S-shaped reciprocating liquid cooling pipelines and diagonal air cooling channels. In terms of control, intelligent switching between multiple modes (heating, gentle cooling, and strong cooling) is achieved based on data fusion from a distributed sensor group. In particular, the system introduces advanced control logic such as fluid residence time optimization, micro-positive pressure protection, and dew point replacement dehumidification, significantly improving the system's energy efficiency ratio and safety.

[0048] Example 1

[0049] This embodiment details the hardware configuration and physical layout of a wide-temperature-range, adaptive energy storage battery thermal management system. Designed for a typical rectangular sealed energy storage chamber 1, the system achieves full-range thermal state control of the battery cluster through a sophisticated fluid network design.

[0050] The core of the system consists of three parts: a controller, a liquid circulation subsystem, and an air circulation subsystem. Unlike traditional independent designs where liquid cooling plates are simply attached to the bottom or air cooling is simply blown, this embodiment adopts an integrated cross-flow diagonal structure.

[0051] In terms of physical space, in this embodiment, the length, width, and height of the battery compartment 1 are defined as the X-axis, Y-axis, and Z-axis, respectively.

[0052] Cooling pipes 14 are arranged along the top and bottom planes of the cabin 1, and the overall fluid flow direction is set along a first direction (e.g., the X-axis, i.e., the front-to-back direction).

[0053] The airflow channel extends along a second direction, which is the diagonal direction connecting the air inlet 16 and the back pressure valve 10 (e.g., the diagonal of the XY plane), forming a non-parallel, three-dimensional oblique relationship with the liquid flow direction in space.

[0054] This cross-flow design not only physically maximizes the contact path between the heat exchange medium and the battery surface, but also thermodynamically constructs a tiered compensation mechanism. When the temperature of the liquid cooling medium gradually increases along the flow path, leading to a decrease in heat exchange capacity, the oblique cold air flow can provide compensatory cooling to the hot tail area at the end of the liquid cooling process, thereby fundamentally disrupting the thermal gradient accumulated along a single flow direction.

[0055] The liquid circulation subsystem is the main force in dealing with high heat loads. In this embodiment, the cooling pipe 14 is not a straight pipe, but is configured as an S-shaped reciprocating arrangement extending and turning back along the first direction.

[0056] When fluid flows inside a bend, it generates a lateral pressure gradient due to centrifugal force, which in turn induces secondary flow. This secondary flow can significantly enhance radial mixing within the fluid and disrupt the laminar boundary layer near the pipe wall, thereby increasing the convective heat transfer coefficient by more than 30% compared to a straight pipe.

[0057] The cooling water inlet 3 and outlet are respectively arranged at relative positions along the first direction (such as the front bulkhead 5 and the rear bulkhead 15) of the battery compartment 1. This opposing arrangement forces the fluid to traverse the entire length of the compartment 1, avoiding short-circuit flow.

[0058] Electrical input connector 6 is located on the left side of the forward bulkhead 5 and is used to connect to external power supply or control signal input. Sensor group communication interface 7 is located in the middle of the forward bulkhead 5 and serves as the communication hub connecting the distributed sensor group (temperature, humidity, flow rate, pressure, etc.) inside the compartment with the external controller. Electrical output connector 8 is located on the right side of the forward bulkhead 5 and is used to output power or feedback signals to the outside. Flange 9 is located at the lower front corner of the right bulkhead 11 and serves as the mounting base interface for the back pressure valve 10.

[0059] Cooling water inlet pipe 4 is connected to cooling water inlet hole 3, and is responsible for introducing external cold water into the cooling water pipeline 14 inside the cabin. Cooling water outlet pipe 12 is connected to cooling water outlet hole 13, and is responsible for exporting the hot water after heat exchange to the cabin and returning it to the external chiller.

[0060] The air circulation subsystem is responsible for temperature control fine-tuning and environmental protection. The air inlet 16 and the back pressure valve 10 are located on two other opposing bulkheads (such as the left bulkhead 2 and the right bulkhead 11) that are different from the liquid cooling interface, and the two are strictly diagonally distributed in space.

[0061] Within a rectangular space, the volume diagonal is the longest distance between two points. By forcing air to flow along the diagonal, the streamlines will naturally cover the central area of ​​the battery cluster and the edge corner areas that are usually prone to dead zones.

[0062] The air inlet 16 is directly connected to an externally integrated hot and cold air fan. This fan features compressor cooling, electric heating (PTC), and dehumidification via a drying impeller, and can output... Temperature-controlled and dry air.

[0063] In liquid cooling systems, trapped air bubbles are a major cause of localized overheating and flow noise. Air bubbles have a much lower thermal conductivity than liquids, and when they adhere to the pipe walls, they create thermal barriers. Therefore, this embodiment specifically specifies that the height of the cooling water inlet 3 in the vertical direction is lower than the height of the cooling water outlet 13. This design utilizes the principle of buoyancy from fluid statics. Since the density of air bubbles is much lower than that of the coolant (water / glycol mixture), they experience upward buoyancy.

[0064] Cooling pipe 14 is configured with a slight upward slope or an overall upward trend. When fluid flows from the lower inlet to the higher outlet, the fluid drag force and buoyancy have the same component, working together to propel air bubbles towards the outlet. This passive venting design, with its low inlet and high outlet, allows the system to quickly vent gas from the pipes during the initial water filling process and continuously carries the precipitated microbubbles out of the chamber 1 and into the expansion tank during operation, ensuring 100% wettability of the inner wall of cooling pipe 14 and greatly improving heat exchange stability.

[0065] The airtightness of the energy storage compartment 1 will inevitably decrease during long-term service. To prevent external moisture, salt spray and dust from seeping in through uncontrolled gaps, this system adopts an active positive pressure protection strategy.

[0066] The system is equipped with a preset opening pressure threshold at the exhaust end (e.g., The back pressure valve 10 is used instead of a traditional straight-through exhaust fan or louver.

[0067] When the external hot and cold air blowers start and supply air into the cabin, the air pressure inside the cabin rises rapidly due to the back pressure valve 10 blocking the exhaust port. The valve only opens to exhaust air when the cabin pressure exceeds the preset opening pressure threshold (which can be set as the sum of the external pressure and a preset value). This ensures that the cabin maintains a slightly positive pressure state that is higher than the external ambient pressure during steady-state operation.

[0068] Due to the pressure gradient from the inside out, the flow direction at any uncontrolled gap (such as where the seal is worn out) can only be gas leakage, and external pollutants cannot diffuse back into the cabin.

[0069] Preferably, this embodiment, in conjunction with a high-efficiency filter at the air inlet, constructs a controlled environment similar to a cleanroom, fundamentally cutting off the deposition path of particulate contaminants on the battery surface.

[0070] To support high-precision adaptive control, this embodiment constructs a sensor network with full coverage. The system focuses not only on the average temperature but also on the uniformity of the temperature distribution. Temperature sensor arrays (NTCs or fiber Bragg gratings) are attached to the surface of the battery clusters, and their layout strategy covers key features of the thermal gradient:

[0071] Cooling water inlet: theoretical lowest temperature zone;

[0072] Cooling water outlet: Theoretical highest temperature zone;

[0073] Central region: The area with the most severe heat accumulation;

[0074] Edge region: The area most affected by ambient temperature.

[0075] The above layout enables the controller to reconstruct the three-dimensional temperature field of the battery cluster in real time, not only calculating the average temperature, but also monitoring the temperature difference and local hot spots.

[0076] Meanwhile, temperature and humidity sensors (SHT series) are deployed at different altitudes inside the cabin and in the external environment to calculate dew point temperature in real time and assess the risk of condensation.

[0077] Flow rate sensors (turbine / ultrasonic) and pressure sensors are integrated into the water and air paths, respectively. This is not only used for feedback control, but also serves as the data foundation for fault diagnosis (such as blockages and leaks).

[0078] Example 2

[0079] like Figure 2 As shown in the figure, this embodiment elaborates on the control method based on the above hardware system. Through advanced algorithms such as multi-level threshold determination, precise PID adjustment, residence time optimization and complex turbulence coordination, the system achieves adaptive operation under all-weather conditions.

[0080] It should be noted that, Figure 2 In this context, PID controller 1 and PID controller 2 represent logic control function modules only. In actual physical implementation, they can be integrated into the same central controller (MCU) or implemented by different controllers.

[0081] At the core of the controller is a finite state machine (FSM), whose state transitions are based on the real-time calculated average temperature of the battery cluster. The system has three preset key temperature thresholds:

[0082] Heating threshold ( ):For example This corresponds to the inflection point of battery performance degradation at low temperatures; below this temperature, active heat dissipation is required.

[0083] First cooling threshold ( ):For example This corresponds to the starting point when the battery begins to generate significant heat accumulation.

[0084] Second cooling threshold ( ):For example This corresponds to a warning point where the battery is approaching the risk of thermal runaway or generating heat under high load.

[0085] in Based on these three thresholds, the system divides the working area into four logical states, and the control logic is as follows:

[0086] 1. Heating mode, such as Figure 3 As shown: When The liquid cooling system is shut down (to avoid introducing additional heat capacity), and the air circulation subsystem activates its heating function, outputting hot air (maximum). The ideal operating temperature range for a battery is typically 20°C to 40°C, and the target temperature value T can be set arbitrarily within this range.

[0087] Specifically, the controller activates the hot and cold air blower, which mainly consists of an air compressor, filter, and dryer. The filtered and dried hot air enters the chamber 1 through the air inlet 16, where it undergoes thorough heat exchange with the battery and electrical components. When the back pressure valve 10 reaches the predetermined pressure relief, it releases exhaust gas, ensuring that the gas pressure inside the chamber 1 remains within its tolerance range. Based on the difference between the average battery cluster temperature and the target temperature, the controller calculates and adjusts the heating power, air velocity V, and air pressure P of the hot and cold air blower in real time, displaying the corresponding air velocity and pressure values ​​in real time via flow rate and pressure sensors. When the average battery cluster temperature reaches the target temperature, the hot and cold air blower stops operating. This embodiment utilizes the good fluidity and strong permeability of hot air to rapidly increase the surface temperature of the battery and the surrounding environment, reduce electrolyte viscosity, and restore battery activity.

[0088] Under low-temperature conditions, the viscosity of the battery electrolyte increases and the ionic conductivity decreases. Forced start-up will lead to severe lithium plating, causing irreversible capacity loss and even safety hazards. The core challenge of the heating mode is that the heater usually has a high power density, while the battery module has a large thermal inertia. Traditional switching control or simple PID control is prone to temperature overshoot. For battery preheating, any overheating exceeding the target temperature (e.g., 25°C) may trigger local hot spots, while frequent heater start-up and shutdown will shorten the actuator life. Therefore, designing a control algorithm that can asymptotically converge, i.e., monotonically approach the setpoint without overshoot, is crucial.

[0089] The asymptotically convergent heating regulation employs a cascade or split-range PID control architecture to decouple the heating actuator (PTC or heat pump) from the heat transfer actuator (fan or pump).

[0090] Define system state variables:

[0091] The average temperature of the battery module, i.e. Figures 2-5 The temperature sensor t (controlled variable PV) is shown in the figure.

[0092] Preheating target temperature (set value SP, usually 20°C).

[0093] Temperature error.

[0094] PID controller output The standard form in the time domain is:

[0095] ;

[0096] in, These are the proportional, integral, and differential gains, respectively.

[0097] To achieve asymptotic convergence and prevent integral saturation and differential impact, an anti-saturation incremental PID algorithm is adopted, and a variable gain scheduling strategy is introduced.

[0098] To ensure a smooth and overshoot-free approximation of the temperature curve. In this embodiment, the heating process is divided into three stages, and the PID parameters are dynamically adjusted:

[0099] Full-speed heating zone ( At this point, the battery temperature is far below the target value, requiring maximum power injection to generate heat; the controller output is saturated (u(t) = 100%). The integral term is frozen to prevent error accumulation from causing overshoot later. Set it to the maximum value.

[0100] Transition adjustment zone ( As the temperature approaches the target, thermal inertia may cause the temperature to continue rising; this introduces a strong differential action (option D). Differential term This is represented here by a damper, which measures the rate of temperature rise. If the temperature rises too quickly, even with some error, term D will produce a negative output, prematurely reducing the heating power. The derivative term differentiates only with respect to the measured value, not the error, to eliminate the impact during setpoint adjustment. .

[0101] asymptotic convergence region ( ): Entering the fine temperature control stage; using critical damping or overdamping tuning. At this time, Decrease, integral term Intervention is used to eliminate steady-state error, but the integral limit is strictly imposed. The output power u(t) will decay exponentially, making... Contact in a monotonically increasing manner, extremely slowly ,make sure when .

[0102] The innovation of this system lies in utilizing a single PID output signal. Simultaneous control of two actuators with different physical characteristics: a heater (heat source) and a fan (heat transfer). This is achieved through split-range control mapping as shown in Table 1.

[0103] Table 1. Logic Layout Mapping Table

[0104] PID output signal u(t) Heater power Fan speed Physical mechanism analysis 0%-10% 0% (Off) Linear decrease (30% to 0%) Waste heat utilization and pressure release stage: Heater shut down. The fan coasts at low speed until it stops, on the one hand removing the waste heat from the heating element to achieve a soft landing; on the other hand, as the speed decreases, the slight positive pressure inside the chamber is gradually unloaded, preventing the back pressure valve 10 from closing violently or causing transient negative pressure due to the sudden stop of the fan. 10%-40% Linear increase (0% to 100%) Constant medium speed (50%) Constant flow field regulation stage: The fan maintains a constant speed to maintain the basic air pressure sufficient to open the back pressure valve 10, ensuring the establishment of a stable micro-positive pressure heat exchange environment. At this time, only the heating power is adjusted to ensure a constant heat transfer coefficient and achieve linear temperature control. 40%-100% 100% (Full Power) Linear increase (50% to 100%) Constant flow field regulation stage: The fan maintains a constant speed to maintain the basic air pressure sufficient to open the back pressure valve 10, ensuring the establishment of a stable micro-positive pressure heat exchange environment. At this time, only the heating power is adjusted to ensure a constant heat transfer coefficient and achieve linear temperature control.

[0105] This actuator decoupling and remapping is key to achieving asymptotic convergence. In particular, when u(t) drops to the low range, the hysteresis shutdown of the fan (controlled by the 0-10% range of the PID output) creates a physical coasting process, which naturally approaches the target temperature using the thermal inertia of the system, fundamentally eliminating the physical cause of overshoot.

[0106] 2. Standby / Natural Cooling Mode: When (For example The system is in standby mode, and the active temperature control functions of both the liquid circulation subsystem and the air circulation subsystem are turned off (or only minimal natural ventilation is maintained).

[0107] This range represents the battery's optimal operating temperature range (comfort zone). Within this range, no active intervention is required; the temperature is maintained by the battery's own thermal inertia and natural heat dissipation from the casing 1, minimizing the need for ineffective start-stop cycles of the fan and water pump, and significantly reducing the system's own operating energy consumption.

[0108] 3. Mild cooling mode, such as Figure 4 As shown: When (For example Only the air circulation subsystem operates, outputting natural cool air or cool air cooled by a compressor.

[0109] Within this temperature range, battery heat generation is moderate. Using only air cooling can significantly reduce system energy consumption (fan power consumption is much lower than that of water-cooled units), while the flowing air removes heat from the battery surface, maintaining a stable temperature. The ideal operating temperature range for a battery is typically 20℃~40℃, and a target temperature value T can be set arbitrarily within this range. This target value is less than... greater than .

[0110] Specifically, the mild cooling mode is as follows: Figure 4 As shown: When the distributed temperature sensor detects that the average temperature at each key location of the battery cluster is between the first and second cooling thresholds, the PID controller controls the hot and cold air blower to activate the cooling function. The filtered and dried cold air enters the chamber 1 through the air inlet 16, where it undergoes sufficient heat exchange. During this process, the back pressure valve 10 plays a crucial role: when the pressure inside the chamber reaches the predetermined pressure relief pressure, the back pressure valve 10 releases exhaust gas, working in conjunction with the intake pressurization to maintain a slight positive pressure inside the chamber, ensuring the gas pressure remains within a safe range. Based on the difference between the average temperature of the battery cluster and the target temperature, as well as the ambient temperature outside the chamber, the controller calculates and adjusts the fan speed V', fan pressure P', and / or the power of the refrigeration compressor in real time.

[0111] The specific strategy is as follows: when the ambient temperature is low, the fan speed is adjusted first to utilize natural cooling; when the ambient temperature is high, the compressor power is increased to reduce the intake air temperature. Simultaneously, flow rate and pressure sensors collect actual operating parameters in real time and feed them back to the controller for closed-loop comparison, rather than simply displaying numerical values. When the average temperature of the battery clusters drops to the target temperature range, the system reduces power or enters a low-power maintenance state.

[0112] In mild cooling mode, the flow rate of the cooling medium (air or coolant) through the battery pack directly determines the efficiency of heat exchange and energy consumption. Excessive flow rate leads to a cubic increase in pump / fan energy consumption, while insufficient flow rate causes the fluid to overheat at the outlet, resulting in a significant temperature difference within the battery module along the flow direction. The residence time optimization control proposed in this embodiment aims to find an optimal fluid residence time to balance heat dissipation uniformity and parasitic energy consumption.

[0113] Duration of stay The residence time is defined as the average time required for a fluid element to pass through the cooling channel of the battery pack. For a channel of length L and cross-sectional area A, when the volumetric flow rate is Q, the residence time is:

[0114] ;

[0115] Where v is the fluid velocity.

[0116] From a thermodynamic perspective, residence time determines the extent to which a fluid absorbs heat. A long residence time (low flow rate) allows the fluid sufficient time to exchange heat with the battery, resulting in an outlet fluid temperature close to the battery temperature. This leads to high heat capacity utilization but results in a large temperature difference between the battery inlet (cold) and outlet (hot), disrupting consistency. A short residence time (high flow rate) allows the fluid to pass through quickly, resulting in a small temperature rise and a uniform battery surface temperature. However, this significantly increases pumping power consumption, and the fluid's heat-carrying capacity is not fully utilized.

[0117] To achieve adaptive control, the controller in this embodiment runs a real-time optimization algorithm. This algorithm is based on the highest battery temperature (i.e., the maximum value among all battery monitoring point temperature data collected by the temperature sensor array). The maximum temperature difference of the battery cluster (i.e., the difference between the highest and lowest temperatures collected by the temperature sensor array). and ambient temperature (the ambient temperature outside the cabin collected by the temperature and humidity monitoring unit). Dynamically find the optimal flow (i.e., optimal residence time) ).

[0118] Construct a weighted cost function J(Q) to minimize the weighted sum of temperature difference and energy consumption:

[0119]

[0120] in:

[0121] The maximum allowable temperature for the battery (e.g., 45°C);

[0122] To allow the maximum temperature difference (e.g., 5°C);

[0123] Power driven by fluid;

[0124] This refers to the maximum nominal power of the equipment in the system used to drive fluid flow (such as a water pump in a liquid-cooled system or a fan in an air-cooled system) when designed to operate at full load.

[0125] These are weighting coefficients that are dynamically adjusted based on the battery state (SOC, charge / discharge rate). For example, during high-rate fast charging, thermal safety is a key factor. Significantly increased; energy consumption weight during static equilibrium. leading.

[0126] Due to the complexity and time-varying nature of the battery thermal model, directly solving for the derivative of the above function on an embedded controller is extremely difficult. Therefore, a Discrete Hill Climbing (DHC) algorithm is used for iterative optimization, specifically including:

[0127] At time k, measure the system state and calculate the current cost. ;

[0128] Apply a small perturbation to the current flow Testing traffic ;

[0129] Waiting and Observing: Maintaining Run a short time window (larger than the fluid transport delay, approximately several seconds), and calculate the new cost after the system's thermal response stabilizes. ;

[0130] like This indicates that the optimization direction is correct; update. ;

[0131] like This indicates an incorrect direction and a reverse disturbance. ;

[0132] The system continuously repeats the above process, ensuring that the operating point always converges to a local minimum of the cost function J. Based on the calculated optimal flow... The optimal flow rate was calculated and used for fan control.

[0133] This algorithm enables the system to automatically find the optimal flow rate under the current operating conditions that "can suppress the temperature rise, ensure uniform temperature, and minimize energy consumption" without needing to accurately predict the battery's heat generation power, thus achieving true operating condition self-adaptation.

[0134] Based on the above-mentioned residence time optimization control of fluid flow rate (v), this embodiment further introduces a method targeting the fluid temperature itself (v). The compressor coordinated control logic. The controller adjusts the control logic based on the ambient temperature ( ) and battery target temperature ( The real-time enthalpy difference determines the supply mode of the cooling source in order to maximize the energy efficiency ratio (EER).

[0135] The controller monitors the ambient temperature outside the cabin in real time and compares it with the preset target temperature of the battery to set the cold source switching threshold. (For example ):

[0136] when At this point, the outside air possesses sufficient cooling potential energy. The controller forcibly shuts down the compressor, operating only the fan. The system relies entirely on the aforementioned discrete hill-climbing algorithm to regulate the flow rate Q, utilizing the sensible heat of the natural wind to dissipate battery heat. In this mode, the system energy consumption is minimized.

[0137] when If the outside air cooling capacity is insufficient, the compressor must be activated to lower the intake air temperature. At this time, the controller executes a constant intake air temperature or a follow-up temperature difference adjustment strategy to perform active cooling.

[0138] Preferably, in active cooling mode, the compressor power... (or rotational speed) The inlet temperature (IH) is no longer a fixed value, but participates in regulation as another control variable. The controller adjusts the compressor power through a PID loop, aiming to control the inlet temperature (IH). Maintain at the optimal setting point .in This is to ensure the subcooling required to achieve the heat exchange temperature difference (e.g., setting the inlet air temperature lower than the battery target). At this point, control commands are generated:

[0139] ;

[0140] in This is the real-time value measured by the air inlet temperature sensor.

[0141] The introduction of the compressor alters the physical parameters in the aforementioned cost function J(Q), and the two constitute cascade cooperative control:

[0142] The compressor turning on lowers the fluid temperature. This increases the heat exchange temperature difference, so that under the same flow rate Q, This significantly reduces the thermal safety term in the cost function.

[0143] compressor power consumption Total energy consumption must be taken into account. Therefore, the energy consumption term in the cost function is revised as follows:

[0144] .

[0145] When the compressor comes into play, the intake air temperature decreases, and the hill-climbing algorithm will automatically detect that maintaining a small flow rate Q is sufficient to meet the heat dissipation requirements.

[0146] Therefore, the system automatically converges to a new equilibrium point: "low flow rate + low temperature air". This avoids the high noise and cubic power consumption caused by high-speed fan operation, while ensuring that the battery temperature is controlled.

[0147] 4. Strong cooling mode, such as Figure 5 As shown: When (e.g., higher than) The air circulation subsystem and the liquid circulation subsystem operate in tandem. The fan outputs strong cold air, and the water pump activates the liquid cooling circulation. In the face of high heat load or thermal runaway risk, the high specific heat capacity and rapid heat absorption of water are utilized to quickly reduce peak heat; at the same time, the high-speed airflow field and the liquid cooling pipeline work together to generate a complex turbulence effect on the battery surface, physically disrupting the thermal boundary layer, maximizing the convective heat transfer coefficient, and rapidly suppressing the battery temperature back to a safe range.

[0148] The PID controller activates the hot and cold air blowers to provide dry, cool air, which enters the compartment 1 through the air inlet 16 on the rear cover for heat exchange. Simultaneously, the PID controller activates the water chiller, pumping chilled water into the cooling water pipes on the inner wall of compartment 1. When the average temperature of the battery clusters reaches the target temperature, both the blowers and the water chiller stop.

[0149] The specific values ​​of the first and second cooling thresholds can be set according to the battery's chemical system and thermal characteristics. In particular, the second cooling threshold is set as a warning value near the battery's thermal runaway critical temperature. When this temperature is reached, it indicates that the battery has a high risk of thermal runaway, and the system needs to simultaneously activate the dual working fluid cycle of air cooling and water cooling to execute a strong cooling mode, using a dual heat dissipation mechanism to quickly suppress the battery temperature to a safe range.

[0150] In fluid heat transfer, the thermal boundary layer is the main source of thermal resistance that hinders heat transfer from the cell surface to the mainstream fluid flow. Especially in laminar flow, where the fluid flows in stratified layers, heat transfer relies primarily on inefficient conduction. The composite turbulence effect proposed in this embodiment aims to actively disrupt the boundary layer and significantly improve the convective heat transfer coefficient (HTC) through the combined effects of physical structure and fluid dynamics.

[0151] According to the Nusselt number According to the definition of ), in forced convection within a pipe, Nu is usually a constant (e.g., 4.36) in laminar flow, while Nu increases significantly with Reynolds number (Re) in turbulent flow.

[0152] In general engineering practice, Re > 2300 is considered the beginning of the transition to turbulent flow, and Re > 4000 is considered fully turbulent flow. Eddies in turbulent flow can penetrate the laminar sublayer and rapidly mix heat from the walls to the center of the fluid.

[0153] This system does not rely on additional flow-disrupting elements, but cleverly utilizes physical structural features to induce complex turbulence. The S-shaped reciprocating arrangement used in this embodiment includes multiple 180-degree bends. According to fluid dynamics principles, when fluid flows through the bends, centrifugal force generates a lateral pressure gradient, inducing a pair of counter-rotating Dean vortices. This strong secondary flow can entrain the mainstream fluid at the center into the wall boundary layer, significantly enhancing radial mixing and thus physically disrupting the laminar sublayer without the need for internal fins.

[0154] Meanwhile, the three-dimensional oblique layout adopted in this embodiment allows the cooling air to sweep across the cooling pipe 14 at a non-parallel angle (oblique cut). When the airflow sweeps across the cylindrical cooling pipe, a wake vortex shedding will be formed on the leeward side of the pipe. This unsteady wake turbulence not only enhances the heat transfer on the outside of the pipe wall, but also further disturbs the fluid inside the pipe through fluid-structure interaction vibration, achieving "internal-external dual turbulence enhancement".

[0155] In the control logic of the forced cooling mode, the system's "preset forced cooling operating parameters" are set based on the critical Reynolds number of the fluid. The controller stores a physical property model of the cooling medium. When forced cooling mode is triggered, the controller no longer performs gentle linear regulation; instead, based on specified wind speed V", wind pressure P", flow velocity v", and water pressure p", it directly commands the water pump and fan in cooling pipe 14 to output a supercritical velocity. This ensures the Reynolds number of the fluid within the pipe is maintained. (e.g., setting goals) At this point, the fluid is forced into the fully turbulent region. In this fully turbulent state, strong random fluctuations exist within the fluid, and the convective heat transfer coefficient Nu is proportional to the 0.8 power of Re. ).

[0156] The control strategy in the strong cooling mode ensures that when the battery faces the risk of thermal runaway, the cooling system can bypass the inefficient laminar flow and transition zone and directly operate at the physical limit point of heat transfer efficiency, thereby maximizing the convective heat transfer coefficient.

[0157] To maximize the heat exchange temperature difference, this embodiment simultaneously implements a "full-power cooling" strategy while increasing the flow rate:

[0158] The controller instructs the compressor in the external hot and cold air blower to operate at its maximum rated power (or a preset high-frequency setting) to forcibly reduce the intake air temperature (e.g., reduce the intake air temperature to a certain level). This ensures that even in high-temperature environments, the air entering cabin 1 has a large heat absorption potential.

[0159] The controller instructs the external chiller unit to operate at maximum cooling load, maintaining the temperature of the coolant pumped into the piping at the system's minimum allowable value (e.g., By utilizing the huge specific heat capacity and low temperature characteristics of water, cryogenic boundary conditions are constructed.

[0160] In summary, the strong cooling mode achieves a multiplier-level increase in convective heat transfer rate through the superposition of supercritical flow rate and maximum cooling power.

[0161] For energy storage compartments using liquid-cooled plates, condensation is a critical safety hazard. When hot and humid ambient air comes into contact with the low-temperature cooling plate or battery surface, if the surface temperature is lower than the air's dew point temperature, water vapor will condense into water droplets. This can lead to electrical short circuits, insulation failure, and even electrochemical corrosion. This embodiment proposes a proactive anti-condensation strategy.

[0162] The controller utilizes temperature and humidity sensors deployed inside the cabin (temperature) humidity The dew point temperature is calculated in real time based on the Magnus Formula. .

[0163] The calculation formula is as follows:

[0164] ;

[0165] ;

[0166] The computation runs at a high frequency (e.g., 1 Hz) in the embedded controller to ensure a rapid response to environmental changes.

[0167] Traditional temperature control systems adjust the coolant temperature based solely on the battery's target temperature. In this system, however, the dew point temperature forms the cooling water temperature setpoint. The lower bound of the hard constraint.

[0168] The control logic enforces the following inequality constraints:

[0169] ;

[0170] in, It is a safety margin (usually 1.5°C~3.0°C) used to compensate for sensor errors and local low temperatures on the cold plate.

[0171] The control logic execution flow is as follows:

[0172] Real-time calculation of cabin dew point temperature If the requested target cooling water temperature Then the controller will force clamping: .

[0173] This means that in humid or rainy weather, even if the battery requires strong cooling, the liquid cooling system will limit the water temperature to prioritize preventing condensation and thus avoid the risk of short circuits.

[0174] This system's active anti-condensation strategy has the highest global control priority. Regardless of whether the system is currently in standby, mild cooling, or strong cooling mode, the controller continuously calculates the cabin dew point temperature in real time. And the coldest physical surface in the system: the real-time temperature of the battery cluster in the cooling water inlet area. Then, a comparison was performed.

[0175] Once a condensation risk is detected, the system will immediately suspend the current thermal management command (or wake up the system) and prioritize the dehumidification operation. This strategy covers the following three typical triggering scenarios:

[0176] Scenario A: Passive wake-up in standby mode.

[0177] When the system is not in operation (such as when it is left to standby at night or in spring and autumn), and the fluid medium stops circulating, the dew point inside the cabin will rise and approach the battery / pipe wall, which is still in a low temperature state, due to sudden changes in the external environment (such as the temperature and humidity rising in the early morning).

[0178] if: ;in For safety thresholds, such as The controller automatically wakes up the air circulation subsystem to perform dehumidification.

[0179] Scenario B: Safety check before starting the mild cooling mode.

[0180] When the battery temperature rises and requests heat dissipation, the controller prepares to start the fan to introduce outside air. If high-humidity outside air is introduced directly, condensation will instantly form upon contact with the low-temperature battery.

[0181] If the current cabin dew point temperature Or, based on calculations, the cabin dew point temperature after the introduction of outside air is estimated. Any value that is close to (i.e., the difference between the battery cluster and the real-time temperature in the cooling water inlet area is less than a set threshold) or higher than the real-time temperature of the battery cluster in the cooling water inlet area. ;

[0182] The system will intercept the regular cooling command and force a dehumidification pretreatment to be performed first. Only after the dew point reaches the standard can it switch to gentle cooling.

[0183] Regarding the estimated dew point temperature Calculation instructions:

[0184] The estimated cabin dew point temperature after the introduction of outside air is essentially calculated based on the temperature and humidity data of the outside environment.

[0185] Specifically, the controller calculates the dew point temperature of the outside air based on the outside temperature and relative humidity collected by the temperature and humidity monitoring unit using the aforementioned Magnus formula (or by consulting the enthalpy-humidity diagram database of humid air).

[0186] Because the air circulation subsystem operates using a positive pressure displacement method, the dew point of the cabin microenvironment will gradually approach the dew point of the outside air after outside air enters cabin 1. Therefore, to ensure safety to the greatest extent, the system directly uses the calculated outside air dew point temperature as the estimated cabin dew point temperature after its introduction.

[0187] If the calculated dew point temperature of the outside air is higher than the surface temperature of the battery water ingress area, the system determines that once the air intake operation is performed, condensation will occur on the battery surface, thereby triggering the above-mentioned anti-condensation interception logic.

[0188] Scenario C: Unlocking capabilities in the strong cooling mode.

[0189] If the system is running or requests to run liquid cooling (forced cooling mode), but the water temperature is forcibly clamped due to anti-condensation logic. If the water temperature doesn't drop, the battery heat cannot be dissipated, creating a "heat-humidity" deadlock: the battery temperature exceeds the upper limit, and the current dew point limit causes the actual water temperature to be higher than the required water temperature. In this case, the active dehumidification function is activated to lower the dew point. This releases the water temperature clamp and restores maximum cooling capacity.

[0190] Once any of the above scenarios is triggered, the controller immediately executes the following closed-loop dehumidification process:

[0191] Step 1: Gas source pretreatment.

[0192] The controller monitors the external relative humidity fed back by a group of sensors. .

[0193] like If the intake air exceeds the preset safe intake threshold: the controller forcibly activates the drying function integrated into the hot and cold air blower (such as compressor condensation dehumidification or adsorption wheel) to deeply dehumidify the intake air.

[0194] like Less than or equal to the preset safe inhalation threshold: directly introduce low-humidity outside air, or supplement with a small amount of heating to reduce relative humidity.

[0195] Step 2: Positive pressure displacement injection.

[0196] The controller instructs the air circulation subsystem to inject the aforementioned dried, low-dew-point air into the cabin. Utilizing the slightly positive pressure environment established by the back pressure valve 10, the original high-humidity / high-dew-point gases in the cabin are systematically replaced and discharged through the exhaust port, physically reducing the absolute moisture content inside the cabin.

[0197] Step 3: Exit and Restore.

[0198] The system continuously monitors humidity parameters and dew point changes inside the cabin.

[0199] When the humidity parameter inside the cabin decreases to below the safe threshold for eliminating the risk of condensation (e.g.) If the dehumidification process ends, the dehumidification process will be terminated.

[0200] If the original scenario was A (standby), the system shuts down the fan and returns to the low-power monitoring state;

[0201] If the original scenario was B (before startup), the system will now execute the mild cooling mode.

[0202] If the original scenario was scenario C (strong cooling deadlock), the system releases the clamping restriction on the cooling water temperature, and the liquid cooling subsystem then operates at the lowest water temperature to maximize heat dissipation efficiency.

[0203] It should be noted that in heating mode, since hot air naturally has the physical properties of reducing relative humidity and increasing the dew point temperature difference, the above logic will not usually be triggered, but the monitoring function will still run in the background just in case.

[0204] Throughout the entire lifecycle of a large-scale energy storage power station, actuator failures in a single subsystem (such as pump shutdown or fan stall) or pipeline anomalies (such as foreign object blockage or joint leakage) are often difficult to detect in a timely manner by traditional switch sensors. To address this, this system constructs a full-dimensional fault-tolerant control system based on model-based and closed-loop deviation monitoring. Utilizing the inherent pressure-flow physical characteristics of the fluid loop, it achieves all-weather health monitoring and fault compensation for the liquid circulation subsystem, air circulation subsystem, and sensor array.

[0205] First, the system established a benchmark reference model based on physical properties.

[0206] During the system debugging phase, the controller calibrates the PQ characteristic curves (i.e., pressure increments) of the pump and fan using a self-learning algorithm. With flow rate Q and rotational speed The data includes the functional relationship between the parameters and the resistance characteristics of the pipeline network. These baseline data are stored in the controller as a basis for subsequent judgments on whether the system is functioning normally. During operation, the controller first calculates the target wind pressure and target water pressure under the current operating conditions based on the battery thermal management requirements (i.e., the difference between the real-time average temperature of the battery cluster and the target set temperature), and uses these as control commands to drive the corresponding subsystems to operate.

[0207] Secondly, perform real-time fault identification based on the "target-actual" deviation.

[0208] The controller uses a sensor array to collect real-time data on actual wind pressure, water pressure, and flow velocity, and performs a closed-loop comparison with the target values. When the deviation between the actual and target values ​​consistently exceeds a preset safety threshold, the system determines that a fault has occurred. To accurately identify the fault type, the algorithm further incorporates residual analysis.

[0209] If the actual pressure is significantly higher than the target value, it is judged as high resistance blockage (such as filter blockage).

[0210] If the actual pressure is significantly lower than the target, it is determined to be a pressure loss leak (such as a pipeline rupture).

[0211] If the physical quantities violate basic physical laws (e.g., the motor is running at full speed but the flow and pressure are both zero), then the sensor is considered to be malfunctioning.

[0212] Finally, the system executes a two-way backup degradation operation strategy based on the fault type to ensure that thermal management never goes offline:

[0213] For liquid cooling subsystem malfunctions (Class A malfunctions): Once a blockage or leak in the liquid cooling circuit is confirmed, the controller immediately physically shuts off the liquid cooling circuit (stops the pump and closes the valve) to prevent the accident from escalating. Subsequently, the system disregards the current temperature range and forcibly activates the air circulation subsystem to enter emergency full-speed air cooling mode, utilizing the backup air heat dissipation path to handle the cooling task. Simultaneously, a power limiting command is sent to the energy management system (EMS) to derate the battery charge / discharge rate, ensuring that the heat generation power does not exceed the air cooling's heat dissipation limit.

[0214] For air circulation subsystem failures (Class B failures): If the fan or intake duct is determined to be faulty, the system immediately shuts down the air-cooling circuit. At this time, even if the battery temperature is within the mild cooling range, the controller will preemptively activate the liquid circulation subsystem for liquid cooling compensation. Specifically, if the failure of air cooling prevents active dehumidification, the system will automatically adjust its anti-condensation strategy by significantly increasing the cooling water temperature setpoint (e.g., maintaining it above the dew point), prioritizing electrical insulation safety while sacrificing some cooling efficiency.

[0215] For sensor malfunctions (Class C malfunctions): If the sensor reading is determined to be drifting or disconnected, the controller will block the feedback signal from the faulty sensor and automatically switch to a model-based open-loop feedforward control mode. In this mode, the controller directly looks up a fixed control command based on the calibrated PQ model, maintaining basic system cooling functionality in blind-open mode and simultaneously issuing a maintenance alarm.

[0216] Through this multi-layered, multi-dimensional fault-tolerance mechanism, the present invention ensures that the energy storage system can still maintain basic safe operation under extreme conditions where any subsystem or sensing unit fails, greatly improving the availability and robustness of the system.

[0217] This embodiment uses, as follows Figure 1 The rectangular energy storage sealed chamber 1 shown is an example, in which energy storage batteries with a total capacity of 67kWh are placed. Under different initial battery temperatures, and with the ambient temperature at room temperature (22℃), the cooling rates of the batteries in three modes are compared: natural rest mode, mild cooling mode, and strong cooling mode. Figure 6 As shown in Table 2.

[0218] Table 2. Statistics on the cooling rate of the battery pack's rectangular energy storage sealed chamber 1.

[0219] Serial Number model cooling rate 1 Natural stillness mode 0.77℃ / h 2 Mild cooling mode 1.07℃ / h 3 Strong cooling mode 1.78℃ / h

[0220] Based on test data from actual cases, with the battery cooling rate of 0.77℃ / h in the natural resting mode as a reference, the average battery temperature cooling rate in the mild cooling mode is 1.07℃ / h, and the average battery temperature cooling rate in the strong cooling mode is 1.78℃ / h. The battery heat dissipation effect is significantly improved compared to the natural resting mode without any measures.

[0221] The contents not described in detail in this specification are existing technologies known to those skilled in the art.

Claims

1. A wide-temperature-range, adaptive energy storage battery thermal management system, characterized in that: include: Controller, liquid circulation subsystem, air circulation subsystem; The controller is used to dynamically adjust the operating status of the liquid circulation subsystem and the air circulation subsystem based on the monitored thermal state parameters; The liquid circulation subsystem and the air circulation subsystem adopt an integrated cross-flow diagonal structure in their physical architecture, forming a composite three-dimensional cross-heat exchange network covering the entire battery cluster, wherein: The liquid circulation subsystem includes cooling pipes arranged along the top and bottom planes of the battery compartment. The cooling pipes are arranged in an S-shaped reciprocating pattern extending and turning back along a first direction. The cooling water inlet and cooling water outlet are respectively arranged on two compartment walls opposite each other along the first direction of the battery compartment. The air circulation subsystem has its flow channel extending along a second direction of the battery compartment. This second direction is the diagonal direction connecting the air inlet and the back pressure valve, and is spatially non-parallel to the first direction, forming a three-dimensional oblique relationship. The air inlet and the back pressure valve are respectively arranged on two other opposing compartment walls that are different from the compartment walls where the cooling water inlet and the cooling water outlet are located, and the two are spatially diagonally distributed. The air inlet is connected to an external hot and cold air fan that integrates a drying and heating module.

2. The wide-temperature-range, adaptive energy storage battery thermal management system according to claim 1, characterized in that: The height of the cooling water inlet hole in the vertical direction is lower than the height of the cooling water outlet hole; the cooling pipe is configured to utilize the height difference to form a fluid channel that facilitates gas discharge.

3. The wide-temperature-range, adaptive energy storage battery thermal management system according to claim 1, characterized in that: The back pressure valve is configured to have a preset opening pressure threshold, so that when the air circulation subsystem is running, in conjunction with the air intake pressurization effect of the external hot and cold air blower, a slightly positive pressure state higher than the external ambient pressure is maintained in the battery compartment, thereby preventing external moisture and particulate pollutants from penetrating into the battery compartment through uncontrolled paths.

4. The wide-temperature-range, adaptive energy storage battery thermal management system according to claim 1, characterized in that: It also includes a distributed sensor array, which is communicatively connected to the controller; the sensor array includes at least: A temperature sensor array is attached to the surface of the battery cluster and its distribution covers the corresponding positions of the battery cluster at the cooling water inlet, outlet, central area and edge area, for real-time monitoring of the overall temperature distribution of the battery cluster. The temperature and humidity monitoring unit is deployed inside and outside the battery compartment and is configured to collect temperature and relative humidity data inside and outside the compartment in real time.

5. A control method based on the system according to any one of claims 1-4, characterized in that... include: The controller collects real-time temperature data at various locations within the battery cluster using a temperature sensor array, and calculates the real-time average temperature of the battery cluster. The method presets a heating threshold, a first cooling threshold, and a second cooling threshold, wherein the heating threshold is less than the first cooling threshold, and the first cooling threshold is less than the second cooling threshold. Based on the comparison between the average battery cluster temperature and the aforementioned thresholds, the controller performs the start-up, shutdown, and adjustment of the fluid medium according to the following logic: When the average temperature of the battery cluster is lower than the heating threshold, the controller instructs the air circulation subsystem to output hot air; When the average temperature of the battery cluster is between the first cooling threshold and the second cooling threshold, the controller only instructs the air circulation subsystem to output cold air; When the average temperature of the battery cluster is higher than the second cooling threshold, the controller instructs the air circulation subsystem to output cold air and instructs the liquid circulation subsystem to activate the liquid cooling function for coordinated operation.

6. The control method according to claim 5, characterized in that: When the average temperature of the battery cluster is lower than the heating threshold, the controller continuously calculates the deviation signal between the real-time average temperature of the battery cluster and the target set temperature; the controller dynamically adjusts the output wind speed and wind pressure of the air circulation subsystem according to the current amplitude, cumulative amount over time and rate of change of the deviation signal, until the average temperature of the battery cluster asymptotically converges to the target set temperature.

7. The control method according to claim 5, characterized in that: When the average temperature of the battery cluster is between the first cooling threshold and the second cooling threshold, the controller adjusts the fan speed of the air circulation subsystem and uses the flow resistance characteristics of the back pressure valve to control the residence time of the introduced external cold air in the battery compartment. By optimizing the residence time, the air medium is ensured to fully absorb battery heat before being discharged from the chamber, thereby maintaining a stable battery temperature without having to activate the liquid circulation subsystem.

8. The control method according to claim 5, characterized in that: When the average temperature of the battery cluster is higher than the second cooling threshold, the controller instructs the liquid circulation subsystem and the air circulation subsystem to operate simultaneously with preset strong cooling operating parameters; by utilizing the synergistic effect of air flow field and liquid cooling, a compound turbulence effect is generated on the battery surface and heat exchange interface, thereby physically destroying or significantly thinning the thermal boundary layer and maximizing the convective heat transfer coefficient.

9. The control method according to claim 5, characterized in that: When the relative humidity outside the cabin detected by the sensor group is higher than the preset safe intake threshold, the controller forcibly activates the drying function integrated by the hot and cold air blower to pre-treat the intake outside air by dehumidification. Meanwhile, the controller calculates the dew point temperature inside the cabin in real time by combining the relative humidity data and temperature data inside the cabin. When the dew point temperature inside the cabin is higher than the real-time temperature of the battery cluster in the cooling water inlet area collected by the temperature sensor array, the controller instructs the air circulation subsystem to inject dehumidified pre-treated air into the cabin to replace the original gas inside the cabin until the humidity parameter inside the cabin is reduced to below the safe threshold for eliminating the risk of condensation.

10. The control method according to claim 5, characterized in that: The controller uses flow rate and pressure sensors deployed in the sensor group to monitor the actual wind pressure and actual water pressure of the air circulation subsystem and the liquid circulation subsystem in real time. The controller uses the target wind pressure and target water pressure calculated based on the difference between the real-time average temperature of the battery cluster and the target set temperature as control commands to drive the corresponding subsystem to operate. The controller performs a closed-loop comparison between the monitored actual wind pressure and actual water pressure and the target wind pressure and target water pressure in real time. When the deviation between the actual value and the target value continues to exceed the preset safety threshold, the controller determines that there is a blockage or leakage fault in the corresponding subsystem and triggers the fault protection logic, enabling the fault-free subsystem to operate in compensation or issuing an alarm to achieve fault-tolerant control of the system.

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