Two-phase cold plate spraying cooperative battery thermal runaway intelligent hierarchical control method and system

Abstract

The invention discloses a two-phase cold plate spraying cooperative battery thermal runaway intelligent hierarchical control method and system, and relates to the technical field of battery thermal control. The two-phase cold plate spraying collaborative battery thermal runaway intelligent hierarchical control method comprises the following steps: S1, collecting and preprocessing thermal state working condition data, component operation data and environment auxiliary data, and constructing a standardized thermal state data set; s2, top evaluation is conducted on the top sudden heat source intensity, and the starting behavior of a spraying device is regulated and controlled; s3, bottom analysis is conducted on the bottom steady-state cooling bearing condition, and the opening degree of a cold plate runner is dynamically adjusted; and S4, performing vertical evaluation on the vertical heat flux coupling characteristics in combination with the local thermal disturbance trend, and performing linkage control on the top spraying frequency and the operation state of the condensation path. The problems that in battery thermal management, a traditional single cooling mechanism is difficult to consider distributed temperature control requirements of bottom steady-state heat absorption and top sudden refrigeration, so that heat flux coupling is uneven, and the local overheating risk is prominent are solved.

Description

Technical Field

[0001] This invention relates to the field of battery thermal control technology, specifically to a two-phase cold plate spray-assisted intelligent hierarchical control method and system for battery thermal runaway. Background Technology

[0002] With the widespread deployment of power battery systems in new energy vehicles, energy storage devices, and industrial emergency power supplies, their thermal management safety has become a key factor affecting the overall operational stability and service life of the system. Current mainstream cooling methods mainly include air cooling, liquid cooling, and phase change heat conduction. Among these, the two-phase cold plate structure, due to its advantages such as strong phase change heat absorption, low thermal resistance, and compact structure, is widely used in the bottom heat dissipation design of battery cell modules, efficiently removing heat from the cell through the evaporation of the working fluid. Simultaneously, to cope with sudden thermal runaway, some systems also integrate spray cooling devices, applying coolant directionally to high-heat points through nozzles to achieve rapid cooling response. Common control strategies typically use cell temperature thresholds, heating rates, or abnormal current fluctuations as triggers to drive the pump and valve modules to switch cooling paths, forming a closed-loop cooling cycle in conjunction with the condenser and return pipeline.

[0003] For example, invention patent CN111505960B discloses a power battery thermal management simulation system and method. This system includes a battery simulation module, a cooling module connected to the battery simulation module, and a control module connected to both the battery simulation module and the cooling module. The control module includes: a control unit connected to the battery simulation module, which acquires the operating temperature of the battery simulation module and outputs a temperature signal based on that temperature; a cooling flow unit connected to both the control unit and the cooling module, which acquires the temperature signal and outputs a flow signal corresponding to the temperature signal to the cooling module; and a cooling temperature unit connected to the cooling module, which outputs a preset temperature signal to the cooling module. This invention allows for flexible control of the power battery thermal management simulation process through the control module, enabling comprehensive simulation analysis of multiple judgment conditions under complex operating conditions.

[0004] For example, invention patent CN115343966B discloses a simulation method for a fuel cell hydrothermal management system, applied to a Modelica-based fuel cell hydrothermal management system. The system includes: a fuel cell stack model, a drive pump model, a PTC heater model, a radiator model, and a first coupling module. The method includes: the first coupling module allocating power from the fuel cell stack model to the radiator model based on the equivalent impedance of the drive pump model and the radiator model; the radiator model analyzing the wind speed of the radiator fan based on the allocated power and performing thermal balance simulation based on the wind speed; and the fuel cell stack model performing power simulation based on the simulation calculations of the radiator model and the drive pump model, and adjusting the power allocated to the radiator model accordingly. This embodiment improves the coupling accuracy between component models.

[0005] However, existing battery cooling control methods generally suffer from problems such as a single response path, delayed triggering mechanisms, and insufficient coupling of resource allocation, making it difficult to adapt to the non-uniform heat dissipation characteristics and zoned cooling requirements exhibited by batteries under various operating conditions. In situations such as short-term cell overload, sudden rise in electrode hotspots, or localized decrease in phase transition efficiency, relying solely on the steady-state heat absorption of the bottom cold plate is often insufficient to suppress heat accumulation in a timely manner. Spray systems may also suffer from wasted cooling or insufficient coverage due to false triggering or delayed response. Furthermore, most systems lack modeling and real-time feedback mechanisms for the coordinated characteristics of top-bottom heat flux in their control logic, failing to dynamically identify the spatial path of thermal runaway development, resulting in a disconnect between cooling measures and the actual location of heat sources.

[0006] To address the above issues, there is an urgent need for a two-phase cold plate spray-assisted intelligent hierarchical control method and system for battery thermal runaway. Summary of the Invention

[0007] Technical problems to be solved

[0008] To address the shortcomings of existing technologies, this invention provides a two-phase cold plate spray coordinated intelligent hierarchical control method and system for battery thermal runaway, which solves the problem that traditional single cooling mechanisms in battery thermal management cannot simultaneously meet the distributed temperature control requirements of bottom steady-state heat absorption and top sudden cooling, resulting in uneven heat flux coupling and prominent local overheating risks.

[0009] Technical solution

[0010] To achieve the above objectives, the present invention provides the following technical solution: a two-phase cold plate spray-coordinated intelligent hierarchical control method and system for battery thermal runaway, comprising: S1, collecting thermal state data, component operation data, and environmental auxiliary data during the two-phase cold plate spray-coordinated thermal management process, and preprocessing the collected thermal state data, component operation data, and environmental auxiliary data to construct a standardized thermal state dataset; S2, based on the standardized thermal state dataset, performing a top assessment of the intensity of the sudden heat source at the top from the temperature change trend in the tab region, and adjusting the opening behavior of the spray device based on the top assessment results; S3, based on the standardized thermal state dataset, performing a bottom analysis of the bottom steady-state cooling load condition, and dynamically adjusting the opening degree of the cold plate flow channel based on the bottom analysis results; S4, using the top assessment results and bottom analysis results as inputs, performing a vertical assessment of the vertical heat flux coupling characteristics in conjunction with the local thermal disturbance trend, and controlling the top spray frequency and condensation path operation status in conjunction with the vertical assessment results.

[0011] Furthermore, the specific steps for collecting thermal state data, component operation data, and environmental auxiliary data during the two-phase cold plate spray coordinated thermal management process are as follows: Collect thermal state data during the two-phase cold plate spray coordinated thermal management process. This thermal state data includes: cell core temperature, tab top surface temperature, cold plate inlet temperature and cold plate outlet temperature, instantaneous flow rate in the main circuit, and cold plate circuit pressure difference. Simultaneously, calculate and record the tab temperature rise rate and the difference between the cold plate inlet temperature and the cold plate outlet temperature. Record the difference between the cold plate inlet temperature and the cold plate outlet temperature as the cold plate inlet-outlet temperature difference. The system collects component operating data, including: spray branch flow rate, steam mass flow rate entering the gas collection hood, condenser inlet temperature, and condenser outlet temperature; it also collects environmental auxiliary data, including: net heat flux of the battery cluster, ambient temperature, battery cluster power, DC bus voltage and DC bus current, power device duty cycle, and controller power consumption; and it calculates the heat absorbed by the condenser using the enthalpy difference method by combining the condenser inlet temperature and condenser outlet temperature, and cross-validates this calculation with the steam mass flow rate to obtain the condensation heat transfer power of the steam in the return path.

[0012] Furthermore, the specific steps for preprocessing the collected thermal state data, component operation data, and environmental auxiliary data to construct a standardized thermal state dataset are as follows: The collected thermal state data is denoised, and the electrode heating rate is calculated based on a sliding time window, while the inlet and outlet temperature difference of the cold plate is obtained; the instantaneous flow rate of the main circuit and the pressure difference of the cold plate circuit are smoothed and filtered to remove instantaneous abrupt interference; in the component operation data, the flow rate of the spray branch is normalized proportionally and the spray activation state is extracted, the steam mass flow rate of the gas collecting hood is smoothed over time, and the inlet and outlet temperature difference of the condenser is used for condensation capacity assessment; the environmental auxiliary data is aligned with a unified timestamp, the net heat flux of the battery cluster is corrected by the battery cell area, and the power is cross-validated through DC bus voltage and DC bus current; the standardized thermal state data, component operation data, and environmental auxiliary data are normalized to construct a standardized thermal state dataset; the complete process of synchronously collecting and preprocessing thermal state data, component operation data, and environmental auxiliary data is recorded as one sampling period.

[0013] Furthermore, the specific steps for evaluating the intensity of the sudden heat source at the top based on the temperature change trend of the tab region using the standardized thermal state dataset are as follows: Add the temperature difference between the top surface of the tab and the core temperature of the cell to the temperature difference between the inlet and outlet of the cold plate, then add one and take the logarithm to obtain the cumulative thermal difference value of the tab core; add one to the tab temperature rise rate and take the logarithm to obtain the normalized top temperature rise value; divide the battery cluster power by the instantaneous flow rate of the main circuit plus one, then add one and take the logarithm to obtain the heat generation flow coupling value; multiply the cumulative thermal difference value of the tab core, the normalized top temperature rise value, and the heat generation flow coupling value to obtain the top cooling evaluation value.

[0014] Furthermore, the specific steps for regulating the operation of the spray device based on the top evaluation result are as follows: real-time comparison of the current top cooling evaluation value with the top cooling threshold: when the top cooling evaluation value is less than or equal to the top cooling threshold, keep the spray device closed and keep the pump frequency unchanged, maintain the current instantaneous volume flow rate of the cold plate, and keep the drainage valve from the gas collection hood to the condenser at the minimum opening; when the top cooling evaluation value is greater than the top cooling threshold, open the solenoid valve of the spray device and switch the pump to the spray liquid supply position, switch the outlet valve of the liquid storage tank to the spray branch and increase the battery cluster power, at the same time open the drainage channel from the gas collection hood to the condenser and increase the condenser condensing air path and liquid path operation position, and increase the instantaneous volume flow rate of the cold plate to the maximum.

[0015] Furthermore, the specific steps for bottom analysis of the steady-state cooling load based on the standardized thermal state dataset are as follows: A temperature-corrected resistance model is constructed by combining the DC bus current and ambient temperature; the instantaneous product of the DC bus voltage and DC bus current is calculated and input into the temperature-corrected resistance model to obtain the conductor Joule loss; the duty cycle of the power device is multiplied by the DC bus current to obtain the conduction loss power; the conductor Joule loss, conduction loss power, and controller power consumption are added to obtain the total loss power of the conductor and power unit; the cold plate loop voltage difference is divided by the instantaneous flow rate of the main loop and then logarithmically added to obtain the flow resistance transport value; the inlet and outlet temperature difference of the cold plate is multiplied by the corresponding temperature difference stability factor and then logarithmically added to obtain the cold plate heat load increment value; the difference between the core temperature of the battery cell and the outlet temperature of the cold plate is divided by the total loss power of the conductor and power unit and then logarithmically added to obtain the core plate temperature difference normalization value; the flow resistance transport value, the cold plate heat load increment value, and the core plate temperature difference normalization value are multiplied to obtain the bottom heat absorption assessment value.

[0016] Further, the specific steps for dynamically adjusting the cold plate flow channel opening based on the bottom analysis results are as follows: Calculate the difference between the bottom heat absorption assessment value of the current sampling period and the bottom heat absorption assessment value of the previous sampling period; when the difference between the bottom heat absorption assessment value of the current sampling period and the bottom heat absorption assessment value of the previous sampling period is positive, increase the speed of the regulating pump and simultaneously increase the main circuit flow rate, continuously increase the opening of the cold plate flow channel distributor towards the main channel side, decrease the opening of the bypass electric valve of the cold plate, and simultaneously increase the opening of the return throttle valve of the liquid storage tank to increase the return flow rate, increase the condenser fan speed and liquid circuit circulation level, and increase the duty cycle of the gas collection hood drainage valve; when the difference between the bottom heat absorption assessment value of the current sampling period and the bottom heat absorption assessment value of the previous sampling period is positive, increase the speed of the regulating pump and simultaneously increase the main circuit flow rate, continuously increase the opening of the cold plate flow channel distributor towards the main channel side, decrease the opening of the cold plate bypass electric valve, and simultaneously increase the opening of the liquid storage tank return throttle valve to increase the return flow rate, increase the condenser fan speed and liquid circuit circulation level, and increase the duty cycle of the gas collection hood drainage valve; when the difference between the bottom heat absorption assessment value of the current sampling period and the bottom heat absorption assessment value of the previous sampling period is positive, increase the speed of the regulating pump and simultaneously increase the main circuit flow rate, continuously increase the opening of the cold plate flow channel distributor towards the main channel side, decrease the opening of the cold plate bypass electric valve, decrease the opening of the liquid storage tank return throttle valve, increase the liquid storage tank return throttle valve, and increase the bottom heat absorption assessment value of the current sampling period and the bottom heat absorption assessment value of the previous sampling period, increase the speed of the regulating pump and the main circuit flow rate, and increase ... When the difference between the heat absorption assessment values ​​is negative, reduce the speed of the regulating pump and simultaneously reduce the main circuit flow rate. Continuously increase the opening of the cold plate flow channel distributor towards the bypass side, increase the opening of the cold plate bypass electric valve, and simultaneously reduce the opening of the liquid storage tank return throttle valve to reduce the return flow. Reduce the condenser fan speed and liquid circuit circulation level, and decrease the duty cycle of the gas collection hood drain valve. When the difference between the bottom heat absorption assessment value of the current sampling period and the bottom heat absorption assessment value of the previous sampling period is zero, keep the regulating pump speed, cold plate distribution and opening, liquid storage tank return throttle valve opening, condenser fan and liquid circuit circulation level, and gas collection hood drain valve duty cycle unchanged, while only keeping the spray device in standby mode without changing its start / stop status.

[0017] Furthermore, the specific steps for vertically evaluating the coupling characteristics of vertical heat flux, using the top evaluation results and bottom analysis results as inputs and combined with the local thermal disturbance trend, are as follows: The vertical temperature difference is obtained by subtracting the cold plate outlet temperature from the top surface temperature of the electrode tab, used to uniformly characterize the difference between the upper and lower thermal fields; simultaneously, the median of the vertical temperature difference within each sampling period is calculated and recorded as the vertical temperature difference benchmark value; the absolute value of the difference between the vertical temperature difference and the vertical temperature difference benchmark value is added by one and then the natural logarithm to the base e is taken to obtain the temperature difference deviation value; the top refrigeration evaluation value is multiplied by the bottom heat absorption evaluation value to obtain the top-bottom synergy value; the condensation heat exchange power is divided by the net heat flux of the battery cluster, added by one, and then multiplied by the spray branch flow rate to obtain the gas-liquid flux value; the temperature difference deviation value is multiplied by the top-bottom synergy value and then divided by the gas-liquid flux value to obtain the vertical heat flux evaluation value.

[0018] Furthermore, the specific steps for controlling the top spray frequency and condensation path operation status based on the vertical evaluation results are as follows: Real-time comparison of the current vertical heat flux evaluation value with the vertical heat flux threshold, which includes a first vertical threshold and a second vertical threshold: When the vertical heat flux evaluation value is less than or equal to the second vertical threshold, the spray device is shut down and kept on standby; the pump speed is adjusted to a low speed and the main circuit flow rate is maintained at its minimum; the opening of the cold plate bypass electric valve remains unchanged and the current flow channel distributor position is maintained; the liquid storage tank outlet valve is switched to the return branch and the return throttle valve is lowered; the duty cycle of the gas collection hood guide valve is adjusted to the minimum; and the condenser fan and liquid circulation speed are adjusted to 25% to 40% of the rated value; when the vertical heat flux evaluation value is greater than the second vertical threshold, the spray device is shut down and kept on standby; the vertical heat flux evaluation value is adjusted to a low speed and the main circuit flow rate is maintained at its minimum; the vertical heat flux evaluation value is adjusted to a low speed and the condenser fan and liquid circulation speed are adjusted to 25% to 40% of the rated value. When the threshold value is less than or equal to the first vertical threshold, the spray device is intermittently turned on, the pump speed is adjusted to maintain the default speed and the main circuit flow rate is increased, the cold plate adjusts the flow channel distributor to the main channel side and reduces the opening of the bypass electric valve, the liquid storage tank outlet valve alternately switches between the spray branch and the return branch, and the condenser fan and liquid circulation gear remain unchanged; when the vertical heat flux assessment value is greater than the first vertical threshold, the spray device is continuously turned on and the nozzle atomization pressure is adjusted to the highest, the pump speed is increased and the main circuit flow rate is increased to the maximum, the cold plate bypass electric valve is closed and the flow channel distributor is fixed to the main channel side, the liquid storage tank outlet valve is fixed to the spray branch and the return throttle valve is adjusted to the maximum, the gas collection hood drainage valve is fully opened, and the condenser fan speed and liquid circulation gear are adjusted to the highest.

[0019] The second aspect of this invention provides a two-phase cold plate spray-coordinated intelligent hierarchical control system for battery thermal runaway, comprising: a multi-source data acquisition module for acquiring thermal state data, component operation data, and environmental auxiliary data during the two-phase cold plate spray-coordinated thermal management process, and preprocessing the acquired thermal state data, component operation data, and environmental auxiliary data to construct a standardized thermal state dataset; a top sudden cooling trigger evaluation module for evaluating the intensity of the top sudden heat source based on the temperature change trend in the tab region according to the standardized thermal state dataset, and controlling the opening behavior of the spray device based on the top evaluation results; a bottom steady-state heat absorption self-consistency module for analyzing the bottom steady-state cooling load condition based on the standardized thermal state dataset, and dynamically adjusting the opening of the cold plate flow channel based on the bottom analysis results; and a vertical collaborative fusion decision module for evaluating the vertical heat flux coupling characteristics by taking the top evaluation results and bottom analysis results as inputs and combining them with the local thermal disturbance trend, and controlling the top spray frequency and condensation path operation status in conjunction with the vertical evaluation results.

[0020] Beneficial effects

[0021] The present invention has the following beneficial effects:

[0022] (1) The two-phase cold plate spray coordinated battery thermal runaway intelligent hierarchical control method and system, by constructing a vertical coordinated cooling structure of cold plate and spray, realizes zoned and precise heat dissipation of steady-state heat source at the bottom of the cell and sudden hot spot at the top, effectively suppressing the expansion path of local thermal runaway.

[0023] (2) The two-phase cold plate spray coordinated battery thermal runaway intelligent hierarchical control method and system realizes the dynamic allocation of cooling resources and the optimization of response rhythm at different heat load stages through the coordinated regulation of main circuit flow, spray intensity and condensation path, thereby improving the overall regulation efficiency of the system.

[0024] (3) The two-phase cold plate spraying coordinated battery thermal runaway intelligent hierarchical control method and system, by introducing steam collection and condenser recovery links, constructs a closed-loop heat exchange path, which improves the cooling medium recycling rate and system energy efficiency while ensuring cooling capacity.

[0025] (4) The two-phase cold plate spraying collaborative battery thermal runaway intelligent hierarchical control method and system, by constructing bottom heat absorption assessment, top cooling assessment and vertical heat flux fusion criteria, forms a complete temperature control judgment chain, which enhances the system's perception accuracy and control closed-loop capability for multi-source thermal disturbances.

[0026] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0027] Figure 1This is a flowchart of the intelligent hierarchical control method for battery thermal runaway with two-phase cold plate spraying coordination according to the present invention.

[0028] Figure 2 This is a structural diagram of the intelligent hierarchical control system for battery thermal runaway with two-phase cold plate spraying coordination according to the present invention;

[0029] Figure 3 This is a line graph showing the vertical heat flux evaluation value involved in this invention;

[0030] Figure 4 This is a flowchart illustrating the battery cooling control process involved in this invention.

[0031] Figure 5 This is a schematic diagram of the battery cooling operation involved in the present invention;

[0032] In the diagram, 1 is the liquid storage tank; 2 is the regulating pump; 3 is the cold plate; 4 is the battery; 5 is the spray device; 6 is the gas collection hood; and 7 is the condenser. Detailed Implementation

[0033] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] Please see Figures 1-5 This invention provides a technical solution: a two-phase cold plate spray-coordinated battery thermal runaway intelligent hierarchical control method and system, including S1, collecting thermal state condition data, component operation data and environmental auxiliary data during the two-phase cold plate spray-coordinated thermal management process, and preprocessing the collected thermal state condition data, component operation data and environmental auxiliary data to construct a standardized thermal state dataset; S2, based on the standardized thermal state dataset, evaluating the intensity of the sudden heat source at the top from the temperature change trend of the tab region, and controlling the opening behavior of the spray device (5) based on the top evaluation result; S3, based on the standardized thermal state dataset, analyzing the bottom steady-state cooling load condition, and dynamically adjusting the flow channel opening of the cold plate (3) based on the bottom analysis result; S4, using the top evaluation result and the bottom analysis result as input, evaluating the vertical heat flux coupling characteristics in combination with the local thermal disturbance trend, and controlling the top spray frequency and condensation path operation status in conjunction with the vertical evaluation result.

[0035] Specifically, the steps for collecting thermal state data, component operation data, and environmental auxiliary data during the two-phase cold plate spray synergistic thermal management process are as follows: Collect thermal state data during the two-phase cold plate spray synergistic thermal management process. This data includes: core cell temperature (reflecting changes in the intensity of the internal heat source); tab top surface temperature (identifying the heat accumulation trend in the conductive connection area); cold plate inlet and outlet temperatures (corresponding to the state changes of the coolant before and after entering and exiting the cold plate, respectively); instantaneous flow rate of the main circuit (describing the current flux level of the liquid cooling cycle); and cold plate circuit pressure difference (assessing the internal resistance and heat transfer load changes of the cold plate). Simultaneously, calculate and record the tab temperature rise rate to describe the dynamic trend of the heat surge in that area, and the difference between the cold plate inlet and outlet temperatures. This difference is the cold plate inlet-outlet temperature difference, used to measure the heat transfer effect of the cold plate section.

[0036] The component operation data includes the spray branch flow rate, which is used to characterize the liquid supply capacity of the spray channel; the steam mass flow rate entering the gas collection hood 6, which is used to reflect the output intensity of the rising steam in the evaporation zone; and the condenser inlet temperature and condenser outlet temperature, which are used to calculate the heat change range before and after the condensation section.

[0037] Collect environmental auxiliary data, including the net heat flux of the battery cell cluster, which describes the effective heat conduction level within the unit structure; ambient temperature, which affects the baseline heat transfer capacity of the cooling system; battery cluster power, which reflects the current load discharge state; DC bus voltage and DC bus current, which are used as the basis for power calculation input; and power device duty cycle and controller power consumption, which are used to identify the internal heat intensity of the controller.

[0038] The heat absorbed by the condenser is calculated by combining the condenser inlet temperature and the condenser outlet temperature using the enthalpy difference method, and cross-validated with the steam mass flow rate. Finally, the condensation heat transfer power of the steam in the return path is obtained, realizing a complete heat flow identification link from evaporation, collection to condensation, and providing quantitative support for subsequent multi-path temperature control strategies.

[0039] This implementation scheme, through the systematic collection of thermal state data, component operation data, and environmental auxiliary data during the two-phase cold plate spray coordinated thermal management process, not only achieves comprehensive perception of key temperature nodes, flow and pressure states, component heat exchange capacity, and environmental load conditions, but also establishes a quantitative assessment path for early identification of thermal runaway by calculating derived indices of cold plate inlet and outlet temperature difference, tab temperature rise rate, and condensation heat transfer power. This step provides real-time, dynamic, and quantifiable data support for subsequent hierarchical control strategies based on vertical heat flux assessment values, ensuring accurate triggering and effective coordinated execution of control strategies.

[0040] Specifically, the steps for preprocessing the collected thermal state data, component operation data, and environmental auxiliary data to construct a standardized thermal state dataset are as follows:

[0041] The collected thermal condition data is denoised, including sliding median filtering of multi-point temperature signals such as the core temperature of the battery cell and the top surface temperature of the electrode to remove outliers caused by transient electromagnetic interference and sensor jitter. Based on this, the electrode heating rate is dynamically calculated based on a rolling time window to identify the short-term rapid heat accumulation trend. At the same time, the difference between the inlet and outlet temperatures of the cold plate is checked for inter-frame continuity to ensure the temporal consistency and physical interpretability of the temperature difference changes at the inlet and outlet of the cold plate. The instantaneous flow rate of the main loop and the differential pressure of the cold plate loop are processed by exponential weighting smoothing to suppress the interference of instantaneous abrupt changes caused by actuator pulsation and loop disturbance, thereby improving the robustness of flow field feature identification. In the component operation data, the flow rate of the spray branch is proportionally normalized according to the nozzle operating range, and the status of the spray device in the current cycle is extracted and marked. The mass flow rate of steam entering the gas collection hood is smoothed by first order according to the time series to highlight the evolution trajectory of the phase change steam release trend. The temperature difference between the inlet and outlet of the condenser is calculated by structured window differential calculation to dynamically evaluate the real-time heat exchange capacity and heat absorption saturation change of the condenser.

[0042] Environmental auxiliary data is uniformly timestamped to eliminate field gaps caused by communication delays and data misalignment; the net heat flux of the cell cluster is corrected in units based on the actual cell surface area to improve the consistency and comparability of energy density indicators; the battery cluster power is back-calculated in real time by multiplying the DC bus voltage and DC bus current, and cross-verified with the controller power consumption data to improve the reliability of power allocation.

[0043] After the above multi-source data has undergone structural analysis and physical constraint verification, it is uniformly normalized to construct a standardized thermal state dataset with unified structure, unified dimensions, and time alignment, providing input support for subsequent state assessment and control classification. Each time the synchronous collection, preprocessing, physical analysis, and standardization integration of thermal state data, component operation data, and environmental auxiliary data is completed, it is marked as a complete sampling cycle, which is used to drive the next step of assessment and control logic update.

[0044] In this implementation scheme, multi-source thermal management data is cleaned, smoothed, normalized, and synchronized to eliminate the influence of sensor noise and transient disturbances. This ensures the consistency of various temperature, flow, pressure, and power signals in the time dimension and their comparability in the physical dimension, thereby forming a standardized thermal state dataset with unified structure and dimensions. This dataset can accurately reflect the heat exchange process between the battery cell and the cold plate, as well as the operating status of the spray and condensation paths. It can also quantify the impact of environmental conditions on the system, providing a reliable data foundation for subsequent thermal runaway identification, graded response determination, and collaborative control logic.

[0045] Specifically, based on a standardized thermal state dataset, the top assessment of the intensity of the sudden heat source at the top, based on the temperature change trend in the tab region, involves the following steps: adding the temperature difference between the top surface of the tab and the core temperature of the cell to the temperature difference between the inlet and outlet of the cold plate, then adding one and taking the logarithm, to obtain the cumulative thermal difference value of the tab core; adding one to the tab temperature rise rate and taking the logarithm, to obtain the normalized top temperature rise value; dividing the battery cluster power by the instantaneous flow rate of the main circuit plus one, then adding one and taking the logarithm, to obtain the heat generation flow coupling value; and multiplying the cumulative thermal difference value of the tab core, the normalized top temperature rise value, and the heat generation flow coupling value to obtain the top cooling assessment value.

[0046] The formula for calculating the top cooling assessment value is:

[0047] ;

[0048] In the formula: This indicates the temperature of the top surface of the electrode tab, used to characterize the level of the top hot spot and the location of sudden heat sources, and is derived from the temperature sensor on the top surface of the battery cell. It indicates the core temperature of the battery cell and is used to characterize the temperature range inside the battery cell. It is derived from the internal temperature of the battery cell and the attached temperature sensor. This indicates the temperature difference between the inlet and outlet of the cold plate, used to quantify the current heat absorption load of the cold plate, and originates from the inlet and outlet temperature sensors of cold plate 3. This indicates the rate of temperature rise of the tab, used to identify a rapid temperature rise at the top, and is derived from the time difference of the temperature at the top surface of the tab. This represents the battery cluster's electrical power, used to estimate the extrapolated discharge heat flux density, and is derived from a power meter. It represents the instantaneous flow rate of the main circuit, used to quantify the bottom convection transport capacity, and is derived from the flow meter between regulating pump 2 and cold plate 3.

[0049] This implementation plan comprehensively evaluates the thermal load and cooling response capability of the top region of the battery pack, quantifying the dynamic relationship between the heat accumulation intensity, heating rate, and cooling capacity of the cold plate at the tabs. By introducing the temperature difference between the tabs and the core, the temperature difference between the inlet and outlet of the cold plate, the heating rate of the tabs, the thermal power of the cell, and the cooling flow rate, an evaluation index that can reflect the top thermal control pressure in real time is constructed. When this evaluation value increases, it indicates a continuous rise in tab temperature, insufficient heat absorption capacity of the cold plate, and a state of severe battery heating and cooling mismatch, which is suitable for the early identification of thermal runaway risk and the triggering basis for spray activation.

[0050] Specifically, the steps for adjusting the activation behavior of the sprinkler device 5 based on the top evaluation results are as follows:

[0051] Real-time comparison of the current top cooling assessment value with the top cooling threshold: When the top cooling assessment value is less than or equal to the top cooling threshold, it is determined that the current top heat load is still within a safe and controllable range. The spray device 5 is kept in the closed state to prevent ineffective heat exchange from causing resource waste. At the same time, the pump 2 is adjusted to maintain the predetermined frequency output, the cold plate 3 continues to maintain the current instantaneous volume flow rate to support steady-state heat exchange, and the drainage valve between the gas collection hood 6 and the condenser 7 is kept at the minimum opening, retaining only the basic steam venting capacity.

[0052] When the top cooling assessment value exceeds the top cooling threshold, an increased heat accumulation trend in the top area is identified. The corresponding solenoid valve of the spray device 5 is immediately activated, and the regulating pump 2 is switched to the spray liquid supply position to increase the spray intensity. The outlet valve of the liquid storage tank 1 is quickly switched to the spray branch. At the same time, the power of the battery cluster is increased to drive active heat dissipation. The flow channel between the gas collection hood 6 and the condenser 7 is further opened, significantly enhancing the steam condensation efficiency. At the same time, the operating positions of the condenser 7's condensing air path and liquid path are increased to release the heat load in the top area in a coordinated manner. The instantaneous volumetric flow rate of the cold plate 3 is also increased to the highest level to ensure that the bottom heat transfer capacity and the top spray mechanism form a linkage response.

[0053] This implementation scheme achieves an intelligent identification and response control mechanism for top heat accumulation trends. By comparing the top cooling assessment value with the top cooling threshold in real time, it dynamically determines whether the current cooling capacity meets the top heat dissipation requirements. When the top heat load is low, the cooling components are kept in a low-power operation state to avoid resource waste. When the top heat accumulation trend intensifies, a linkage control strategy of spray activation, condensation path optimization, and flow rate increase is automatically triggered to achieve rapid response and precise cooling of high heat flux density areas, thereby effectively suppressing the overheating risk at the tab location and improving the overall thermal stability and operational safety of the battery.

[0054] Specifically, based on a standardized thermal state dataset, the bottom steady-state cooling load condition analysis is performed using the following steps: A temperature-corrected resistance model is constructed by combining the DC bus current and ambient temperature. The instantaneous product of the DC bus voltage and DC bus current is calculated and input into the temperature-corrected resistance model to obtain the conductor Joule loss. The duty cycle of the power device is multiplied by the DC bus current to obtain the conduction loss power. The conductor Joule loss, conduction loss power, and controller power consumption are added to obtain the total loss power of the conductor and power unit. The cold plate circuit voltage difference is divided by the instantaneous flow rate of the main circuit, and then logarithm is added to obtain the flow resistance transport value. The inlet and outlet temperature difference of the cold plate is multiplied by the corresponding temperature difference stability factor, and then logarithm is added to obtain the cold plate heat load increment value. The difference between the core temperature of the battery cell and the outlet temperature of the cold plate is divided by the total loss power of the conductor and power unit, and then logarithm is added to obtain the core plate temperature difference normalization value. The flow resistance transport value, the cold plate heat load increment value, and the core plate temperature difference normalization value are multiplied to obtain the bottom heat absorption assessment value.

[0055] The formula for calculating the bottom heat absorption assessment value is:

[0056] ;

[0057] In the formula: This represents the instantaneous flow rate of the main circuit, used to quantify the bottom convection transport capacity, and originates from the flow meter between regulating pump 2 and cold plate 3; This represents the pressure difference in the cold plate circuit, used to reflect the pressure drop caused by flow resistance and phase change, and originates from the inlet and outlet pressure difference sensing of cold plate 3; This indicates the temperature difference between the inlet and outlet of the cold plate, used to quantify the current heat absorption load of the cold plate, and originates from the inlet and outlet temperature sensors of cold plate 3. It indicates the core temperature of the battery cell and is used to characterize the temperature range inside the battery cell. It is derived from the internal temperature of the battery cell and the attached temperature sensor. This indicates the outlet temperature of the cold plate, used to measure the temperature difference between the cold plate and the core temperature of the battery cell. It is derived from the outlet temperature sensor of the cold plate 3. It represents the total power loss of the conductor and power unit, used to quantify the steady-state heat source that can be derived from the cold plate 3, and is derived from the power meter and loss calculation; The temperature difference stability factor, ranging from 1 to 3, is used to adjust the response weight of temperature differences to the bottom heat absorption assessment value. It is derived from the fluctuation stability characteristics of the inlet and outlet temperature difference sequence of the cold plate within the current hot channel within a sliding window. In the specific calculation process, firstly, the time series of the inlet and outlet temperature difference of the cold plate within the current sampling period is extracted, and based on this series, the local trend slope, mean square volatility, and differential gradient between adjacent sampling points are constructed to characterize the continuity and stability of the current temperature difference change. Then, the temperature difference characteristic baseline of the cold plate during its historical steady-state operation is extracted to form a steady-state template including the mean range, fluctuation bandwidth, and the proportion of outliers. By comparing the temperature difference change index within the current window with the steady-state template in multiple dimensions, the amplitude deviation ratio, trend fit, and overlap of abnormal frequency bands are calculated. Finally, combined with the steady-state level assessment of the corresponding operating channel of the cold plate under historical operating conditions, a temperature difference stability aggregate score is constructed, ultimately generating the temperature difference stability factor. When the current temperature difference changes drastically, fluctuates frequently in direction, and deviates from the historical steady-state template, the value of the temperature difference stabilization factor is increased to suppress the nonlinear amplification effect of such unstable temperature differences on the bottom heat absorption assessment value; conversely, if the temperature difference sequence is stable and the fluctuation bandwidth fluctuates within the steady-state threshold, the temperature difference stabilization factor is decreased to improve the sensitivity and dynamic adaptability of the heat absorption index to the real stable operating conditions.

[0058] This implementation scheme quantifies the overall heat absorption capacity and cooling response status of the bottom of the cold plate. By jointly analyzing the cooling path pressure difference, the temperature difference between the inlet and outlet of the cold plate, the core heat load of the battery cell, and the temperature gradient, it identifies potential flow resistance anomalies, heat absorption hysteresis, and thermal conduction imbalances at the bottom of the cold plate. The formula structure adopts a three-segment logarithmic factor multiplication form, corresponding to the flow driving capacity, the transient heat absorption intensity of the cold plate, and the thermal coupling efficiency between the core and the cold plate, respectively. A temperature difference stabilization factor is introduced to dynamically adjust the response sensitivity to unsteady-state disturbances, thereby achieving high-precision assessment and early risk warning of changes in bottom cooling performance, providing key input basis for subsequent control logic.

[0059] Specifically, the steps for dynamically adjusting the opening of the cold plate's three flow channels based on the bottom analysis results are as follows:

[0060] The difference between the bottom heat absorption assessment value in the current sampling period and the bottom heat absorption assessment value in the previous sampling period is calculated to identify the dynamic trend of the bottom heat absorption capacity of the cold plate, and the liquid flow rate, valve opening and condensation reflux rhythm are adjusted accordingly.

[0061] When the difference between the bottom heat absorption assessment value of the current sampling period and the bottom heat absorption assessment value of the previous sampling period is positive, it indicates that the bottom heat absorption capacity has increased and the accumulated heat load needs to be released quickly. At this time, the speed of the regulating pump 2 is increased and the main circuit flow rate is increased simultaneously. The opening of the flow channel distributor of the cold plate 3 is continuously adjusted to a larger value on the main channel side, compressing the flow space of the bypass passage and reducing the actual opening of the bypass electric valve of the cold plate 3. At the same time, the opening of the return throttle valve of the liquid storage tank 1 is increased to improve the overall return flow, drive the fan speed of the condenser 7 to increase the liquid circuit circulation level synchronously, and thus enhance the heat exchange capacity. In addition, the duty cycle of the duct valve of the gas collection hood 6 is increased to extend the single exhaust cycle and improve the steam discharge efficiency.

[0062] When the difference between the bottom heat absorption assessment value of the current sampling period and the bottom heat absorption assessment value of the previous sampling period is negative, it indicates a decrease in heat absorption capacity. To avoid energy waste and flow path disturbance, the speed of pump 2 is adjusted back appropriately and the main circuit flow is reduced simultaneously. The opening of the flow channel distributor of cold plate 3 is continuously expanded to the bypass side. The bypass electric valve of cold plate 3 is opened to reduce the load on the main channel. At the same time, the opening of the return throttle valve of liquid storage tank 1 is reduced to slow down the flow rate of the condensation circuit. The fan speed and liquid circulation gear of condenser 7 are reduced, and the duty cycle of the vent 6 is adjusted accordingly.

[0063] When the difference between the bottom heat absorption assessment value of the current sampling period and the bottom heat absorption assessment value of the previous sampling period is zero, it indicates that the heat absorption state tends to be stable. All control parameters remain unchanged at their current values. The speed of pump 2, the flow channel configuration of cold plate 3, the throttling degree of liquid storage tank 1, the operating load of condenser 7 and the exhaust frequency of gas collection hood 6 are adjusted to maintain the current level. At the same time, the spray device 5 is kept in standby state to prevent sudden disturbances, but no start-stop switching is performed.

[0064] In this implementation scheme, based on the difference trend of the bottom heat absorption assessment value in the continuous sampling period, the change direction of the bottom heat absorption capacity of the cold plate is dynamically identified, and the pump speed, the opening of the cold plate main bypass flow channel, the return flow distribution, the condenser heat exchange level and the exhaust cycle of the gas collection hood are adjusted accordingly, so as to realize the real-time control of the bottom heat dissipation capacity, and ensure the dynamic adaptability of the cell heat conduction path under different operating conditions and the flow stability of the cooling channel.

[0065] Specifically, the vertical evaluation of the coupling characteristics of vertical heat flux is carried out using the top evaluation results and bottom analysis results as inputs, combined with the local thermal disturbance trend. The specific steps are as follows: the vertical temperature difference is obtained by subtracting the cold plate outlet temperature from the top surface temperature of the electrode tab, which is used to uniformly characterize the difference between the upper and lower thermal fields; at the same time, the median of the vertical temperature difference in each sampling period is calculated and recorded as the vertical temperature difference benchmark value; the absolute value of the difference between the vertical temperature difference and the vertical temperature difference benchmark value is added by one and then the natural logarithm with base e is taken to obtain the temperature difference deviation value; the top refrigeration evaluation value is multiplied by the bottom heat absorption evaluation value to obtain the top-bottom synergy value; the condensation heat exchange power is divided by the net heat flux of the battery cluster, added by one, and then multiplied by the spray branch flow rate to obtain the gas-liquid flux value; the temperature difference deviation value is multiplied by the top-bottom synergy value and then divided by the gas-liquid flux value to obtain the vertical heat flux evaluation value.

[0066] The formula for calculating the vertical heat flux assessment value is as follows:

[0067] ;

[0068] In the formula: It represents the vertical temperature difference, used to reflect the level of unevenness in the upper and lower thermal fields, and originates from the temperature sensing of the top surface of the tab and the outlet of the cold plate. This represents the baseline value for vertical temperature difference, used to construct the adaptive deviation, and is derived from the median value over a recent period. This represents the top cooling assessment value, used to characterize the intensity of top cooling demand. This represents the bottom heat absorption assessment value, used to characterize the steady-state load-bearing capacity of the cold plate. The flow rate of the spray branch is used to characterize the liquid injection intensity at the top and is derived from the branch flow meter of the spray device 5. The condensation heat transfer power recovered by the gas collecting hood 6 and the condenser 7 is used to characterize the real-time heat carried away by the steam recovery path, which is derived from the calculation of steam mass flow rate and condensation temperature difference; This represents the current net heat flux of the battery cell cluster, used to normalize the exhaust capacity, and is derived from electrical power and irreversible heat statistics.

[0069] In this implementation example, the vertical temperature difference of Example 1 is set to 12.0, the vertical temperature difference baseline value is 5.0, the top cooling evaluation value is 2.5, the bottom heat absorption evaluation value is 1.8, the spray branch flow rate is 1.2, the condensation heat exchange power is 3.5, and the net heat flux of the battery cell cluster is 1.5.

[0070] In Example 2, the vertical temperature difference is set to 10.5, the baseline value for vertical temperature difference is 4.5, the top cooling assessment value is 2.8, the bottom heat absorption assessment value is 2.0, the spray branch flow rate is 1.3, the condensing heat exchange power is 3.8, and the net heat flux of the battery cluster is 1.6.

[0071] In Example 3, the vertical temperature difference is set to 14.0, the baseline value for vertical temperature difference is 6.0, the top cooling assessment value is 3.0, the bottom heat absorption assessment value is 1.9, the spray branch flow rate is 1.1, the condensing heat exchange power is 4.0, and the net heat flux of the battery cluster is 1.4.

[0072] In Example 4, the vertical temperature difference is set to 13.5, the baseline value for vertical temperature difference is 5.5, the top cooling assessment value is 2.6, the bottom heat absorption assessment value is 2.2, the spray branch flow rate is 1.4, the condensation heat exchange power is 3.2, and the net heat flux of the battery cluster is 1.3.

[0073] In Example 5, the vertical temperature difference is set to 15.0, the baseline value for vertical temperature difference is 6.0, the top cooling assessment value is 3.2, the bottom heat absorption assessment value is 2.1, the spray branch flow rate is 1.3, the condensation heat exchange power is 3.6, and the net heat flux of the battery cluster is 1.7.

[0074] In Example 6, the vertical temperature difference is set to 11.0, the baseline value for vertical temperature difference is 4.0, the top cooling assessment value is 2.4, the bottom heat absorption assessment value is 1.7, the spray branch flow rate is 1.2, the condensing heat exchange power is 3.3, and the net heat flux of the battery cluster is 1.5.

[0075] In Example 7, the vertical temperature difference is set to 13.0, the baseline value for vertical temperature difference is 5.0, the top cooling assessment value is 2.9, the bottom heat absorption assessment value is 2.0, the spray branch flow rate is 1.1, the condensing heat exchange power is 3.7, and the net heat flux of the battery cluster is 1.4.

[0076] The vertical heat flux assessment values ​​for each instance were calculated, as shown in Table 1.

[0077] Table 1. Vertical Heat Flux Assessment Data

[0078]

[0079] like Figure 3 As shown, this is a line graph of the vertical heat flux evaluation value provided in the example of this application. (See Table 1 and...) Figure 3As can be seen, Example 5 has the highest vertical heat flux assessment value, reflecting its significant vertical temperature difference, good synergy between top cooling and bottom heat absorption, strong condensation heat transfer capacity, and large net heat flux of the battery cluster. Overall, this demonstrates excellent stratified matching and flux control capabilities of the vertical heat transfer structure under this condition, making it a typical example for high heat flux density control. In contrast, Example 6 has the lowest vertical heat flux assessment value. Although its top cooling and condensation heat transfer data remain at a moderate level, the smaller vertical temperature difference and lower net heat flux result in a weaker overall assessment value, indicating insufficient vertical heat transfer intensity and limited system regulation efficiency under this condition. It should be considered a secondary example in the control reference. The line graph of the vertical heat flux assessment value can intuitively show the differences in the comprehensive heat transfer adaptability, heat flow channel response capability, and condensation recovery linkage performance of each example, providing key quantitative basis for further identifying representative operating conditions and optimizing the synergistic strategy of upper and lower heat zones.

[0080] Specifically, based on the vertical assessment results, the steps for controlling the top spray frequency and the condensation path operation status are as follows: Real-time comparison of the current vertical heat flux assessment value with the vertical heat flux threshold, where the vertical heat flux threshold consists of a first vertical threshold and a second vertical threshold.

[0081] When the vertical heat flux assessment value is less than or equal to the second vertical threshold, immediately shut down the spray device 5 and keep it in standby mode, adjust the speed of pump 2 to reduce to low speed, synchronously reduce the main circuit flow to the minimum limit, keep the opening of the bypass electric valve of cold plate 3 unchanged and do not adjust the current distribution of the flow channel distributor, switch the outlet valve of liquid storage tank 1 to the return branch path and gradually lower the return throttle valve, set the duty cycle of the duct valve of gas collection hood 6 to the minimum value within the current support range, and reduce the overall operation level of the condenser 7 fan and liquid circuit circulation to the range of 25 to 40 of the rated capacity.

[0082] When the vertical heat flux assessment value is greater than the second vertical threshold but does not exceed the first vertical threshold, the spray device 5 adopts an intermittent start strategy to respond to the current heat flow demand, the pump 2 is adjusted to the default speed, the main circuit flow rate is increased to a moderate range, the internal structure of the cold plate 3 performs the flow channel distributor adjustment operation to the main channel side, and at the same time slowly reduces the opening of the bypass electric valve, the outlet valve of the liquid storage tank 1 dynamically switches between the spray branch and the return branch as needed, and the condenser 7 fan and liquid circuit circulation maintain the existing operating state without adjustment;

[0083] When the vertical heat flux assessment value exceeds the first vertical threshold, the spray device 5 is immediately activated and the nozzle output pressure is increased to the highest atomization level. Simultaneously, the speed of the regulating pump 2 is increased to the peak value to maximize the liquid supply flow rate of the main circuit. The bypass electric valve of the cold plate 3 performs a fully closed action and locks the flow distributor in the main channel. The outlet valve of the liquid storage tank 1 is fixed in the spray liquid supply path, and the opening of the return throttle valve is adjusted to the maximum limit. The duct valve of the gas collection hood 6 is switched to the fully open state. The fan speed and liquid circulation operation mode of the condenser 7 are fully activated and enter the highest performance mode.

[0084] like Figure 4 The diagram shown is a flowchart of the battery cooling control involved in this invention, covering key components and decision nodes in the cooling path, and reflecting the linkage control process of spray response and heat flow regulation. Starting from the storage tank in the upper left corner, the coolant is pressurized by a regulating pump and enters the cold plate, where primary heat exchange occurs between the cold plate and the heat source. Simultaneously, a temperature sensor monitors the temperature rise in real time. The system then assesses for early signs of thermal runaway. If a sign is detected, a spray system is immediately activated for rapid heat suppression, while a gas recovery hood collects vapor and sends it to the condenser for gas-liquid separation and heat recovery. If no sign is detected, the basic cooling process is maintained, with the coolant returning from the condenser to the storage tank in a closed-loop cycle, ensuring stable operation. Throughout the process, the regulating pump speed plays a crucial role in coordinated control, dynamically matching the cooling intensity under different operating conditions. The spray system and the cold plate form a dual-channel response mechanism for the cooling path, ensuring rapid cooling and risk control capabilities in the face of sudden thermal runaway. The gas recovery hood and the condenser establish a heat recovery link, enabling closed-loop operation and refrigerant recycling under high heat flux conditions. The overall process features clear decision-making, rapid response, and a closed-loop path.

[0085] like Figure 5 The diagram illustrates the battery cooling operation of this invention, comprising a storage tank, regulating pump, cold plate, battery, spray device, gas collection hood, and condenser. The storage tank 1 stores and outputs coolant, providing a basic guarantee for coolant supply. The regulating pump 2 adjusts the coolant circulation flow rate in the main circuit, and its output is connected to the cold plate structure. The cold plate 3 is in close contact with the surface of the battery (numbered 4), serving to receive the heat source and perform initial heat exchange. The spray device 5 is positioned above the battery to spray atomized coolant under high heat flux conditions to enhance the cooling effect. The gas collection hood 6 is installed above the battery to collect the vaporized refrigerant during the spraying process and guide its return flow. The condenser 7 is located below the structure and condenses the vapor returning from the gas collection hood, ultimately recovering the liquid refrigerant back to the storage tank, forming a complete circulating cooling path. The diagram clearly shows the connection relationships and functional distribution between the core modules: storage, supply, heat absorption, spraying, gas-liquid recovery, and condensation heat exchange.

[0086] In this implementation scheme, based on the real-time trend of the vertical heat flux assessment value, the spray device, regulating pump, internal flow channel structure of cold plate, outlet path of liquid storage tank, gas collection hood diversion component and condenser operation status are dynamically linked and controlled to achieve precise adjustment of cooling capacity distribution, atomized spray intensity and return path switching under different vertical heat flux levels. This ensures the timeliness of the overall cooling structure response, liquid circuit circulation efficiency and condensation recovery stability under complex heat load distribution conditions, and improves the adaptability and steady-state maintenance capability of the overall thermal management architecture.

[0087] The second aspect of this invention provides an intelligent hierarchical control system for thermal runaway of a two-phase cold plate spray-coordinated battery, comprising: a multi-source data acquisition module, used to acquire thermal state condition data, component operation data and environmental auxiliary data during the two-phase cold plate spray-coordinated thermal management process, and to preprocess the acquired thermal state condition data, component operation data and environmental auxiliary data, including filtering, normalizing and time synchronization processing of multi-dimensional data such as temperature, flow rate, pressure, power, and ambient temperature and humidity, to construct a standardized thermal state dataset, ensuring that the subsequent evaluation module has a stable and highly comparable input basis;

[0088] The top-sudden cooling trigger assessment module is used to extract key features from the temperature change rate, temperature rise gradient and fluctuation amplitude of the battery cell tab area based on a standardized thermal state dataset, quickly identify the intensity of the top sudden heat source and form a top assessment result. When the assessment result is higher than the trigger threshold, the opening behavior and atomization intensity of the spray device 5 are adjusted in real time to deal with the sudden heat source.

[0089] The bottom steady-state heat absorption self-consistent module is used to continuously evaluate the heat load distribution, flow channel temperature difference and heat capacity of the cold plate 3 during steady-state operation based on a standardized thermal state dataset, identify its cooling capacity boundary, and dynamically adjust the flow channel opening and flow velocity distribution structure of the cold plate 3 accordingly to ensure effective heat conduction at the bottom.

[0090] The vertical collaborative fusion decision module is used to evaluate the coupling strength of vertical heat flux by taking the top evaluation results and bottom analysis results as inputs, combined with the heat flow disturbance frequency, temperature difference response hysteresis and the change of heat drive gradient between the upper and lower layers. Based on the evaluation results, it controls the opening frequency and duration of the top spray device, and dynamically adjusts the air path operation status and liquid path circulation rhythm of the condenser 7 to achieve optimized control of heat flux distribution with coordinated upper and lower layers and timely response.

[0091] In this implementation plan, the multi-source data acquisition module is responsible for comprehensively collecting various types of data generated during the two-phase cold plate spray coordinated thermal management process, including cell thermal status, component operation data and environmental auxiliary parameters, and preprocessing these data to construct a unified standardized thermal status dataset, providing a reliable input basis for subsequent evaluation and control modules.

[0092] The top-mounted sudden cooling trigger assessment module, based on a standardized thermal state dataset, focuses on the temperature change trend in the top tab area of ​​the battery cell. By analyzing the temperature rise rate and temperature difference abrupt change characteristics, it identifies whether there is a sudden heat source at the top and generates a top thermal intensity assessment result accordingly. This result will be used to decide whether to quickly activate the spray device 5 and its spray intensity parameters, enabling rapid response and cooling control to high thermal disturbance events.

[0093] The bottom steady-state heat absorption self-consistent module mainly evaluates the heat absorption capacity and thermal balance state of the cold plate 3 during steady-state operation. Combining the bottom flow channel temperature difference, heat flux density, and flow distribution data, it dynamically determines its cooling capacity boundary. Based on the evaluation results, the opening structure of the cold plate flow channel and the coolant flow distribution are adjusted to achieve precise adaptation of the bottom region to the steady-state heat load.

[0094] The vertical collaborative fusion decision module takes the assessment results of the top sudden heat source and the bottom steady-state heat absorption analysis results as inputs, integrates the vertical temperature difference evolution trend of the battery cell with the heat flux coupling characteristics, performs a comprehensive vertical heat flux assessment, and accordingly controls the opening frequency and duration of the spray device 5, while simultaneously adjusting the fan speed and liquid circulation rhythm of the condenser 7, to achieve thermal management collaborative optimization between rapid response at the top and continuous heat absorption at the bottom.

[0095] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0096] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A two-phase cold plate spray-assisted intelligent hierarchical control method for battery thermal runaway, characterized in that: include: S1 collects thermal state data, component operation data and environmental auxiliary data during the two-phase cold plate spray coordinated thermal management process, and preprocesses the collected thermal state data, component operation data and environmental auxiliary data to construct a standardized thermal state dataset. S2, based on the standardized thermal state dataset, the intensity of the sudden heat source at the top is evaluated from the temperature change trend of the electrode area, and the opening behavior of the spray device (5) is adjusted based on the top evaluation results. S3, based on the standardized thermal state dataset, performs bottom analysis on the bottom steady-state cooling load condition, and dynamically adjusts the flow channel opening of the cold plate (3) based on the bottom analysis results; S4 uses the top evaluation results and bottom analysis results as inputs, combines the local thermal disturbance trend to perform a vertical evaluation of the vertical heat flux coupling characteristics, and controls the top spray frequency and condensation path operation status based on the vertical evaluation results.

2. The intelligent hierarchical control method for battery thermal runaway with two-phase cold plate spraying as described in claim 1, characterized in that: The specific steps for collecting thermal status data, component operation data, and environmental auxiliary data during the two-phase cold plate spray synergistic thermal management process are as follows: Thermal status data during the two-phase cold plate spray coordinated thermal management process are collected. The thermal status data includes: cell core temperature, tab top surface temperature, cold plate inlet temperature and cold plate outlet temperature, main circuit instantaneous flow rate, and cold plate circuit pressure difference. At the same time, the tab temperature rise rate and the difference between the cold plate inlet temperature and the cold plate outlet temperature are calculated and recorded. The difference between the cold plate inlet temperature and the cold plate outlet temperature is recorded as the cold plate inlet and outlet temperature difference. Collect component operation data, including: spray branch flow rate, steam mass flow rate entering the gas collection hood (6), condenser inlet temperature and condenser outlet temperature; Collect environmental auxiliary data, including: net heat flux of battery cell cluster, ambient temperature, battery cluster power, DC bus voltage and DC bus current, power device duty cycle and controller power consumption; The heat absorbed by the condenser is calculated by combining the condenser inlet temperature and the condenser outlet temperature using the enthalpy difference method and cross-validated with the steam mass flow rate to obtain the condensation heat transfer power of the steam in the return path.

3. The intelligent hierarchical control method for battery thermal runaway with two-phase cold plate spraying as described in claim 1, characterized in that: The specific steps for preprocessing the collected thermal state data, component operation data, and environmental auxiliary data to construct a standardized thermal state dataset are as follows: The collected thermal condition data are denoised, and the electrode heating rate is calculated based on a sliding time window, while the temperature difference between the inlet and outlet of the cold plate is obtained. The instantaneous flow rate of the main circuit and the pressure difference of the cold plate circuit are smoothed and filtered to remove instantaneous change interference. In the component operation data, the flow rate of the spray branch is normalized proportionally and the spray activation status is extracted. The steam mass flow rate of the gas collection hood is smoothed over time. The temperature difference between the inlet and outlet of the condenser is used to evaluate the condensation capacity. The environmental auxiliary data are aligned with a unified timestamp. The net heat flux of the battery cell cluster is corrected by the battery cell area. The power is cross-verified by the DC bus voltage and DC bus current. The standardized thermal condition data, component operation data, and environmental auxiliary data are normalized to construct a standardized thermal condition dataset. A complete process of synchronously collecting and preprocessing thermal condition data, component operation data, and environmental auxiliary data is recorded as one sampling cycle.

4. The intelligent hierarchical control method for battery thermal runaway with two-phase cold plate spraying as described in claim 1, characterized in that: The specific steps for top-level assessment of the intensity of the sudden heat source at the top based on the temperature change trend in the electrode region using a standardized thermal state dataset are as follows: Add the temperature difference between the top surface of the electrode and the core temperature of the cell to the temperature difference between the inlet and outlet of the cold plate, and then add one and take the logarithm to obtain the cumulative thermal difference value of the electrode core. Add one to the temperature rise rate of the tab and take the logarithm to obtain the normalized value of the top temperature rise. Divide the battery cluster power by the instantaneous flow rate of the main circuit plus one, then add one and take the logarithm to obtain the heat generation flow coupling value; The top cooling evaluation value is obtained by multiplying the cumulative thermal difference of the tab core, the normalized top temperature rise value, and the coupled value of the heat flow rate.

5. The intelligent hierarchical control method for battery thermal runaway with two-phase cold plate spraying as described in claim 1, characterized in that: The specific steps for regulating the activation behavior of the spray device (5) based on the top evaluation results are as follows: Real-time comparison of the current top cooling assessment value with the top cooling threshold: When the top cooling assessment value is less than or equal to the top cooling threshold, keep the spray device (5) closed and keep the frequency of the regulating pump (2) unchanged, the cold plate (3) maintains the current instantaneous volume flow rate, and keep the drain valve from the gas collection hood (6) to the condenser (7) at the minimum opening. When the top cooling assessment value is greater than the top cooling threshold, open the solenoid valve of the spray device (5) and switch the regulating pump (2) to the spray liquid supply position, switch the outlet valve of the liquid storage tank (1) to the spray branch and increase the power of the battery cluster, open the drainage channel from the gas collection hood (6) to the condenser (7) and increase the condenser air path and liquid path operation position of the condenser (7), and increase the instantaneous volume flow rate of the cold plate (3) to the maximum.

6. The intelligent hierarchical control method for battery thermal runaway with two-phase cold plate spraying as described in claim 1, characterized in that: The specific steps for bottom analysis of the steady-state cooling load condition based on the standardized thermal state dataset are as follows: A temperature-corrected resistance model is constructed by combining the DC bus current and ambient temperature. The instantaneous product of the DC bus voltage and DC bus current is calculated and input into the temperature-corrected resistance model to obtain the conductor Joule loss. The duty cycle of the power device is multiplied by the DC bus current to obtain the conduction loss power. The conductor Joule loss, conduction loss power and controller power consumption are added to obtain the total loss power of the conductor and power unit. Divide the pressure difference in the cold plate circuit by the instantaneous flow rate in the main circuit, add a logarithm, and obtain the flow resistance transport value. Multiply the temperature difference between the inlet and outlet of the cold plate by the corresponding temperature difference stability factor, add one and take the logarithm to obtain the incremental value of the cold plate heat load. Divide the difference between the core temperature of the battery cell and the outlet temperature of the cold plate by the total power loss of the conductor and power unit, and then add a logarithm to obtain the normalized value of the core plate temperature difference. The bottom heat absorption assessment value is obtained by multiplying the flow resistance transport value, the cold plate heat load increment value, and the core plate temperature difference normalization value.

7. The intelligent hierarchical control method for battery thermal runaway with two-phase cold plate spraying as described in claim 1, characterized in that: The specific steps for dynamically adjusting the flow channel opening of the cold plate (3) based on the bottom analysis results are as follows: Calculate the difference between the bottom endothermic assessment value in the current sampling period and the bottom endothermic assessment value in the previous sampling period: When the difference between the bottom heat absorption assessment value of the current sampling period and the bottom heat absorption assessment value of the previous sampling period is positive, increase the speed of the regulating pump (2) and simultaneously increase the flow rate of the main circuit, continuously increase the opening of the flow channel distributor of the cold plate (3) towards the main channel side, reduce the opening of the bypass electric valve of the cold plate (3), and at the same time increase the opening of the return throttle valve of the liquid storage tank (1) to increase the return flow, increase the fan speed and liquid circulation gear of the condenser (7), and increase the duty cycle of the gas collection hood (6) duct valve; When the difference between the bottom heat absorption assessment value of the current sampling period and the bottom heat absorption assessment value of the previous sampling period is negative, reduce the speed of the regulating pump (2) and simultaneously reduce the flow rate of the main circuit, continuously increase the opening of the flow channel distributor of the cold plate (3) to the bypass side, increase the opening of the bypass electric valve of the cold plate (3), and at the same time reduce the opening of the return throttle valve of the liquid storage tank (1) to reduce the return flow, reduce the fan speed and liquid circulation gear of the condenser (7), and reduce the duty cycle of the duct valve of the gas collection hood (6); When the difference between the bottom heat absorption assessment value of the current sampling period and the bottom heat absorption assessment value of the previous sampling period is zero, the speed of the regulating pump (2), the distribution and opening degree of the cold plate (3), the opening degree of the return throttle valve of the liquid storage tank (1), the fan and liquid circulation gear of the condenser (7) and the duty cycle of the gas collection hood (6) diversion valve remain unchanged, while only the spray device (5) is kept in standby state without changing the start and stop.

8. The intelligent hierarchical control method for battery thermal runaway with two-phase cold plate spraying as described in claim 1, characterized in that: The specific steps for vertically evaluating the coupling characteristics of vertical heat flux, using the top evaluation results and bottom analysis results as inputs and combining them with local thermal perturbation trends, are as follows: The vertical temperature difference is obtained by subtracting the cold plate outlet temperature from the top surface temperature of the electrode tab, which is used to uniformly characterize the difference between the upper and lower thermal fields; at the same time, the median of the vertical temperature difference in each sampling period is calculated and recorded as the vertical temperature difference benchmark value. The temperature deviation value is obtained by adding one to the absolute value of the difference between the vertical temperature difference and the vertical temperature difference reference value, and then taking the natural logarithm to the base e. Multiply the top cooling assessment value by the bottom heat absorption assessment value to obtain the top-bottom synergy value; Divide the condensation heat exchange power by the net heat flux of the battery cluster, add one, and then multiply by the flow rate of the spray branch to obtain the gas-liquid flux value. Multiply the temperature difference deviation value by the top-bottom synergy value and then divide by the gas-liquid flux value to obtain the vertical heat flux assessment value.

9. The intelligent hierarchical control method for battery thermal runaway with two-phase cold plate spraying as described in claim 1, characterized in that: The specific steps for controlling the top spray frequency and condensation path operation status based on the vertical evaluation results are as follows: The current vertical heat flux assessment value is compared with the vertical heat flux threshold in real time. The vertical heat flux threshold includes a first vertical threshold and a second vertical threshold. When the vertical heat flux assessment value is less than or equal to the second vertical threshold, shut down the spray device (5) and keep it on standby, adjust the speed of the pump (2) to the low speed and keep the main circuit flow at the minimum, keep the opening of the bypass electric valve of the cold plate (3) unchanged and keep the current flow channel distributor position, switch the outlet valve of the liquid storage tank (1) to the return branch and lower the return throttle valve, adjust the duty cycle of the gas collection hood (6) drain valve to the minimum, and adjust the fan and liquid circulation gear of the condenser (7) to 25% to 40% of the rated value; When the vertical heat flux assessment value is greater than the second vertical threshold and less than or equal to the first vertical threshold, the spray device (5) is turned on intermittently, the speed of the pump (2) is adjusted to maintain the default speed and the main circuit flow is increased, the cold plate (3) adjusts the flow channel distributor to the main channel side and reduces the opening of the bypass electric valve, the outlet valve of the liquid storage tank (1) alternates between the spray branch and the return branch, and the fan and liquid circulation gear of the condenser (7) remain unchanged; When the vertical heat flux assessment value is greater than the first vertical threshold, the spray device (5) is continuously turned on and the nozzle atomization pressure is adjusted to the highest level, the speed of the regulating pump (2) is increased and the main circuit flow rate is increased to the maximum level, the bypass electric valve of the cold plate (3) is closed and the flow channel distributor is fixed on the main channel side, the outlet valve of the liquid storage tank (1) is fixed on the spray branch and the return flow throttle valve is adjusted to the maximum level, the vent hood (6) duct valve is fully opened, and the fan speed and liquid circulation gear of the condenser (7) are adjusted to the highest level.

10. A two-phase cold plate spray-coordinated intelligent hierarchical control system for battery thermal runaway, employing the two-phase cold plate spray-coordinated intelligent hierarchical control method for battery thermal runaway as described in any one of claims 1-9, comprising: The multi-source data acquisition module is used to collect thermal status data, component operation data and environmental auxiliary data during the two-phase cold plate spray coordinated thermal management process, and to preprocess the collected thermal status data, component operation data and environmental auxiliary data to construct a standardized thermal status dataset. The top sudden cooling trigger evaluation module is used to evaluate the intensity of the top sudden heat source based on the temperature change trend of the electrode area based on the standardized thermal state dataset, and to control the opening behavior of the spray device (5) based on the top evaluation results. The bottom steady-state heat absorption self-consistent module is used to perform bottom analysis on the bottom steady-state cooling load condition based on the standardized thermal state dataset, and dynamically adjust the flow channel opening of the cold plate (3) based on the bottom analysis results; The vertical collaborative fusion decision module is used to evaluate the vertical heat flux coupling characteristics by taking the top evaluation results and bottom analysis results as inputs and combining them with the local thermal disturbance trend. Based on the vertical evaluation results, it also controls the top spray frequency and the condensation path operation status in a coordinated manner.

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