System and method for controlling battery preconditioning in a work machine

Abstract

A battery-powered work machine includes a control system to determine a threshold state of charge of the battery at which an operator is solicited for an instruction whether to precondition the battery for fast charging. The control system evaluates various current parameters in the machine, such as battery cell temperature, ambient temperature, battery state of health, battery size, and capacity of the battery thermal management system, to determine an expected change in state of charge resulting from preconditioning the battery. A buffer amount of charge is added to define the threshold state of charge. When the threshold exceeds the current state of charge of the battery, the control system provides a notification through an operator interface for the operator to select or reject fast charging with battery preconditioning.

Description

Technical Field

[0001] This disclosure relates throughout to a system and method for controlling the preconditioning of a battery that powers a work machine, and more specifically, to a control system for the work machine that notifies the operator of the option to charge the battery during operation based on the anticipated decrease in battery charge caused by the preconditioning. Background Technology

[0002] Heavy-duty machinery, such as earthmoving vehicles or transport trucks, requires significant power to function. These machines can be quite heavy, and their loads require considerable power to move. Diesel engines have traditionally provided this power, but they can have drawbacks. For example, diesel fuel supplies may be located far from transport routes or work sites, and diesel machinery can generate substantial pollution. Non-combustion power sources, such as rechargeable lithium-ion batteries, offer numerous advantages over diesel engines, including the ability to achieve high torque levels and environmental friendliness.

[0003] When a battery (or a series of batteries) is used as a power source for machinery, frequent charging may be required to increase its state of charge (SoC) to the desired level, which can interrupt the machinery's operation. Charging energy is most efficiently transferred to the cells at a temperature or temperature range that depends on the battery cell's chemistry (but is typically around 15 to 35 degrees Celsius (60 to 95 degrees Fahrenheit)). At these temperatures, the battery can charge faster than at higher or lower temperatures. When charging speed is not critical, such as in so-called slow charging that might occur overnight at low power, battery temperature is usually not a major issue. When attempting to charge the battery quickly, such as in so-called fast charging at high power, maintaining the battery's optimal temperature affects charging efficiency and therefore charging speed. Adjusting the battery temperature to this value during preparation for and during a charging event is often referred to as pre-conditioning.

[0004] Electric vehicles typically include a battery thermal management system (BTMS) to regulate battery temperature during pre-conditioning and in other situations where improved battery performance and lifespan are required. When operating as an active thermal system, a BTMS may include cooling sections, heating sections, and a circulating fluid that transfers heat to or from the battery to affect its temperature. While this helps prepare for fast charging, using an active thermal system to pre-condition the battery can reduce the system's overall energy consumption (SoC), thereby reducing the operating range and maneuverability of the machinery.

[0005] A method for initiating battery preconditioning in a vehicle using operator input is described in U.S. Patent Application Publication No. 2022 / 0250506A1 (“'506 application”). Battery-powered passenger vehicles tend to have a more stable SoC consumption rate than heavy-duty work machinery, and '506 application describes a process for preconditioning a vehicle battery by manually requesting or by predicting the vehicle’s arrival at a charging station using an automated system. In coordination with a navigation system, this automated system can use predictive intelligence to provide the probability of a charging event occurring at a known charging station based on the vehicle’s location and time, and synchronize the preconditioning event with arrival at the charging station. However, '506 application does not consider that work machinery may consume large and unpredictable amounts of energy in a sudden manner when it has moved less than a few hundred meters from the work site or lacks navigation assistance. '506 application also does not consider that the operational requirements of heavy-duty work machinery often make extensive interaction with the operator interface during work undesirable and dangerous. Therefore, the control system of '506 application does not provide an ideal method for controlling battery preconditioning in work machinery operating at a work site.

[0006] The examples disclosed herein are intended to overcome the shortcomings of such systems. Summary of the Invention

[0007] In one aspect of this disclosure, a working machine includes: a working implement; one or more actuators positioned to apply force to the working implement; a battery configured to power the working machine and having a state of charge (SoC) and a battery cell temperature; and a sensor positioned to detect at least the SoC and the battery cell temperature. The working machine also includes: a battery thermal management system (BTMS) configured to regulate the battery cell temperature; an operator interface configured to receive input and display output related to the operation of the working machine; and an electronic controller at least communicatively coupled to the BTMS and the operator interface. The electronic controller is configured to: receive input from the sensor related to the SoC and the battery cell temperature; and determine an expected change in the SoC caused by pre-regulating the battery under current operating conditions. Based at least in part on this expected change in the SoC, the electronic controller is configured to: determine a threshold SoC at which a notification associated with the need to charge the battery is provided on the operator interface. When the threshold SoC is exceeded, the electronic controller is configured to: provide the notification on the operator interface and monitor the operator interface to obtain a response to the notification, wherein the response includes a request for fast charging or a rejection of fast charging. If no response is received within a predetermined time after the notification, the electronic controller is configured to: command the BTMS to pre-regulate the battery.

[0008] In another aspect of this disclosure, a control system within a work machine includes: a battery configured to power the work machine, the battery having a state of charge (SoC) and a cell temperature; a battery thermal management system (BTMS) configured to regulate the cell temperature using an active thermal mode and a passive thermal mode; an operator interface; and an electronic controller. The electronic controller is configured to: calculate, under the current operating conditions of the work machine, an expected decrease in the SoC caused by the BTMS adjusting the cell temperature to a pre-regulated temperature; and determine a threshold SoC based at least in part on the expected decrease in the SoC, at which a notification related to pre-regulating the battery is communicated. Once the SoC equals the threshold SoC, the electronic controller is configured to: communicate the notification via the operator interface; and receive a response to the notification via the operator interface, wherein the response includes a request for fast charging or a rejection of fast charging. Based on the response, the electronic controller is further configured to: instruct the BTMS to use the active thermal mode and the passive thermal mode to regulate the cell temperature.

[0009] In another aspect of this disclosure, a computer-implemented method includes: receiving data related to current operating conditions of a battery-powered operating machine, the current operating conditions including ambient temperature and the battery cell temperature; and calculating, by the electronic controller, an expected decrease in the state of charge (SoC) of the battery caused by adjusting the battery cell temperature to a pre-regulated temperature by a battery thermal management system (BTMS) under the current operating conditions. Based at least in part on the expected decrease in the SoC, the method includes: determining a threshold SoC, providing a notification related to pre-regulating the battery at the threshold SoC; comparing the SoC with the threshold SoC; and conveying the notification via an operator interface after the SoC equals the threshold SoC. The method further includes: receiving a response related to the notification via the operator interface; and, in response to the response, instructing the BTMS to adjust the battery cell temperature. Attached Figure Description

[0010] Please refer to the accompanying drawings for a detailed description. In the drawings, the leftmost number of the reference numerals indicates the first figure in which the reference numeral appears. The same reference numerals indicate similar or identical items.

[0011] Figure 1 This is a schematic illustration of an electric working machine according to the examples of this disclosure.

[0012] Figure 2 This is a schematic block diagram of a control system according to an example of the present disclosure, the control system including... Figure 1The battery thermal management system within the electric operating machinery.

[0013] Figure 3 It is based on the example of this disclosure. Figure 1 A graphical representation of the charge capacity of the battery inside an electric work machine.

[0014] Figure 4 It is based on the example of this disclosure. Figure 1 The graphical layout of the operator interface in the electric operating machinery.

[0015] Figure 5 This is a flowchart depicting a method for controlling battery pre-conditioning in a working machine according to an example of this disclosure. Detailed Implementation

[0016] According to the principles of this disclosure, a working machine powered by a battery or battery array includes a control system for determining a threshold state of charge (SOC) of the battery. The threshold SOC indicates the battery charge level at which the control system seeks instruction from the operator whether to pre-condition the battery for fast charging. The control system can evaluate various current parameters in the machine, such as battery cell temperature, ambient temperature, battery health, battery size, rate of change of SOC, and the capacity of the battery thermal management system, to determine the expected change in SOC resulting from pre-conditioning the battery. A buffer amount of charge can be added to the expected change in SOC to obtain the threshold SOC. During operation of the working machine, when the threshold SOC exceeds the battery's current SOC, the control system provides a notification via an operator interface, asking the operator to choose or refuse fast charging for battery pre-conditioning. The control system then manages the battery temperature according to the operator's instruction, or initiates pre-conditioning without instruction, so that the working machine is ready to accept fast charging to allow the working machine to perform additional activities in a short period. Several examples of implementing the principles of this disclosure are described below.

[0017] Figure 1A side view of a work machine 100 is illustrated as an example of a pre-conditioning system suitable for battery power and control according to this disclosure. The exemplary work machine 100 is a wheel loader, a type of heavy machinery having four wheels and a front-mounted bucket for loading, carrying, and moving materials. Wheel loaders are also referred to as front loaders, bucket loaders, scoop loaders, and tipper loaders. In other specific embodiments, the work machine 100 may not require a transport load and may be any machinery associated with a variety of industrial applications, including but not limited to mining, agriculture, forestry, construction, and other industrial applications. The principles of this disclosure can be applied to any work machine powered by a non-flammable source, such as a battery. These machines may include, for example, pavers, cold planers, graders, backhoe loaders, wheel loaders, harvesters, excavators, automatic graders, skid steer loaders, tractors, bulldozers, transport trucks, etc.

[0018] refer to Figure 1 Example machine tool 100 includes a frame 102 with an operator cab 104. The operator cab 104 provides a enclosure for accommodating one or more operators of the machine tool 100. Typically, within the operator cab 104, an operator interface 106 provides the operator with tools to interact with and control the activities of the machine tool 100. For example, the operator interface 106 may include a joystick 108 to receive input from the operator, thereby inducing and controlling the actions of the machine tool 100. As shown, the operator interface 106 may also include a monitor 110 that can provide feedback and status information to the operator via one or more of analog, digital, and / or touchscreen displays. In some options, the monitor 110 includes devices for the operator to input to the machine, such as via a keyboard, mouse, touchscreen, arrow keys, selector buttons, or any other suitable features for recording manually entered data. In various examples, the monitor 110 may also display one or more additional buttons, icons, and / or other controls operable to control various corresponding functions of the machine tool 100, as discussed below. In other options, monitor 110 and / or other components of operator interface 106 can be configured to receive such input via voice recognition, gesture recognition, and / or other input methods. Thus, operator interface 106 allows operators to understand and monitor the performance of the machine 100 from information displayed on a screen (such as monitor 110), and may also interact with joystick 108 to influence the machine's behavior.

[0019] The work machinery 100 includes a non-combustion power source, which includes at least a battery 112 mounted on or within a frame 102. The battery 112 of the work machinery 100 may include one or more batteries, such as lithium-ion (Li-ion) batteries, lithium-ion polymer batteries, nickel-metal hydride (NiMH) batteries, lead-acid batteries, nickel-cadmium (Ni-Cd) batteries, zinc-air batteries, nickel-sodium chloride batteries, or other types of batteries. In some examples, multiple battery cells may be combined in series or parallel within a battery module. Multiple battery modules may, in turn, be combined in series within a battery string. One or more battery strings may be disposed within a battery pack, such as a set of battery strings connected in parallel. Therefore, the battery 112 may include one or more battery packs, battery strings, battery modules, and / or battery cells. The battery 112 provides at least a portion of the power to various systems operating the work machinery 100. In this way, the work machinery 100 may be a battery electric machine (BEM), a battery electric vehicle (BEV), a hybrid vehicle, a fuel cell and battery hybrid vehicle, or another mobile machinery at least partially powered by the battery 112.

[0020] Battery 112 provides electrical energy to various components to be converted into mechanical energy within the work machinery 100. For example, work machinery 100 includes a powertrain 116 that may include drive motors, transmissions (e.g., electric transmissions), reduction drives, inverters, drive shafts, one or more shafts, and / or other components associated with an electric drive system. Drive motors may be in the form of electric motors, electric motors, electrical conversion systems, electric drive systems, and / or other electrical components operatively coupled to battery 112. These motors and systems are configured to convert and / or utilize energy stored in battery 112 to cause overall movement of work machinery 100, and / or to cause movement of individual work tools and other components of work machinery 100. In some examples, powertrain 116 may include an internal combustion engine (not shown) for hybrid power (e.g., together with battery 112) of work machinery 100. Battery 112 may also provide energy to power other components of work machinery 100, such as controllers, cooling systems, displays, actuators, sensors, etc.

[0021] Through the powertrain 116, the battery 112 can drive a set of ground-mounted elements 114 mounted on the frame 102, such as Figure 1 The wheels are shown in the diagram. The ground engagement element 114 may additionally or alternatively include tracks, rails, etc. When the drive motor of the powertrain 116 is energized, the drive motor consumes energy stored in the battery 112 to rotate the ground engagement element 114, thereby enabling the working machine 100 to traverse a surface (typically the ground).

[0022] In addition, the work machinery 100 may have one or more braking systems (not shown), such as a service braking system, a regenerative braking system, and / or a regenerative braking system. The service braking system may be a hydraulic braking system or other braking system configured to press brake pads against the rotor to frictionally slow the wheels of the work machinery 100. The regenerative braking system may be configured to capture kinetic and / or potential energy during braking and / or deceleration of the work machinery 100, and to store the captured energy in a battery 112. The regenerative braking system may be a dynamic braking system configured to similarly capture kinetic and / or potential energy during braking and / or deceleration of the work machinery 100, and to dissipate the energy as heat in one or more resistors within the work machinery 100.

[0023] To assist in performing work functions, the work machinery 100 may include work implements 118 (such as... Figure 1 The bucket shown is coupled to the frame 102. The working implement 118 can be driven by at least one actuator 120 (such as...). Figure 1 The illustrated hydraulic linkage is operated. Alternatively, other forms of work implements and actuators for causing movement and manipulation of the work implements may be used.

[0024] In some situations, the work equipment 100 may be positioned to travel around a restricted work site to perform work or tasks, such as moving or transporting soil materials. For this purpose, when the SoC of the battery 112 becomes low, the work equipment 100 may travel from a charging station to one or more work locations within the work site, and then to the same or different charging stations. In some cases, the work equipment 100 may deplete most or all of its battery capacity without traveling more than a few hundred meters from a charging station.

[0025] The work machinery 100 can be a manned machine, a semi-autonomous machine, or an autonomous machine. In the example where the work machinery 100 is a manned or semi-autonomous machine, a human operator or driver can typically operate, control, or guide some or all of the functions of the work machinery 100 from within the operator's cab 104. However, in the example where the work machinery 100 is autonomous or semi-autonomous, the functions of the work machinery 100 (such as steering, speed adjustment, tool positioning and movement, and / or other functions) can be fully or partially automatically or semi-automatically controlled by onboard and / or offboard controllers or other computing devices associated with the work machinery 100.

[0026] The controller (also known as an electronic control module or unit (ECM 130)) coordinates with the operator interface 106 to provide centralized processing and control for the machine 100. The term "controller" is intended to be used in its broadest sense to include one or more controllers and / or microprocessors that can be associated with and cooperate with the machine 100 to control various functions and operations of the machine. The functionality of the ECM 130 can be implemented in hardware and / or software, without regard to the functionality itself. The ECM 130 may include a memory and a processing unit that can store instructions or algorithms in data form, and the processing unit is configured to perform operations based on these instructions. The memory can be any suitable computer-accessible or non-transitory storage medium for storing computer program instructions, such as RAM, SDRAM, DDR SDRAM, RDRAM, SRAM, ROM, magnetic media, and optical media. The ECM 130 can be a single controller or multiple controllers that work together to perform various tasks. ECM 130 may include one or more microprocessors, field-programmable gate arrays (FPGAs), digital signal processors (DSPs), and / or other components configured to generate compaction plans, one or more travel paths for the working machine 100, and / or other information useful to the operator of the working machine 100. Many commercially available microprocessors can be configured to perform the functions of ECM 130. Various known circuits can be associated with ECM 130, including power supply circuits, signal conditioning circuits, actuator drive circuits (i.e., circuits supplying power to solenoids, motors, or piezoelectric actuators), and communication circuits. In some examples, ECM 130 is located on the working machine 100, while in other examples, ECM 130 is located at an external and / or remote location relative to the working machine 100.

[0027] like Figure 1 As shown, the work equipment 100 additionally includes a battery thermal management system (BTMS) 132. BTMS 132 is a fluid system that provides heating or cooling to regulate the temperature of the battery 112 under various conditions. As is known to those skilled in the art, the performance, health, and lifespan of the battery 112 can be affected by its operating temperature. Depending on the chemistry of the cells within the battery 112, the most efficient pre-regulation temperature can be in the temperature range of approximately 15 to 35 degrees Celsius (60 to 95 degrees Fahrenheit). At any given time, for example, due to ambient temperature caused by weather at the work site of the work equipment 100, or due to heat generated by the battery 112, powertrain 116, or other components within the work equipment 100, the temperature of the battery 112 may be higher or lower than its most efficient charging temperature.

[0028] BTMS 132 may include several components configured to operate in either an active or passive thermal mode, coordinated by ECM 130, based on the thermal and energy states of the operating machinery 100. In active thermal mode, energy is drawn from battery 112 to activate heating elements to add heat to the fluid system, or to activate a cooler to extract heat from the fluid system to adjust the temperature of battery 112 accordingly. In passive thermal mode, energy is typically not drawn from battery 112 to regulate temperature. Instead, battery temperature can be regulated using convection and conduction through radiators on the fluid system, based on the temperature difference between the battery and the surrounding environment.

[0029] Starting from the overall structure of the exemplary operating machine 100, Figure 2 A schematic block diagram illustrating a control system 200 and an exemplary BTMS 132 according to the principles of this disclosure is shown. Typically, the control system 200 may include at least an ECM 130 that communicates with and is communicatively coupled (e.g., via electrical and / or wireless connections) to an operator interface 106 to control and coordinate the functions of various components within the BTMS 132, at least via one or more sensors 250. Figure 2 As shown in the lower left corner, at least one of the sensors 250 may be associated with and possibly positioned near the battery 112 to detect its operating conditions. These battery operating conditions may include battery cell temperature, the battery's current SoC, and the battery's state of health (SoH), such as the battery 112's ability to retain charge, receive charge, and / or transfer energy at a certain power level. The sensor 250 is configured to transmit parameters about these conditions as data to the ECM 130. The sensor 250 may be located at other locations within the BTMS 132 to detect temperature and other operating conditions independently or under instruction from the ECM 130 and transmit them to the ECM 130.

[0030] When operating in passive thermal mode, the BTMS 132 uses a surrounding... Figure 2 The schematic block diagram shows a peripheral fluid path 202 exchanging heat with the battery 112. The fluid path 202 includes a pipe, conduit, or similar conduit or channel containing a heat-conducting fluid, which can be a liquid such as water, ethylene glycol, propylene glycol, ethylene glycol, or a refrigerant or a combination thereof. Figure 2 As roughly illustrated, fluid path 202 extends from battery 112 through valve 204 to reach... Figure 2 The rightmost passive core 206 passes through valve 208 to reach pump 210 and returns to battery 112.

[0031] Fluid path 202 is positioned such that the heat-conducting fluid within fluid path 202 contacts, passes through, or is positioned to thermally affect the battery 112 due to the temperature difference between the fluid and the battery 112. During passive thermal mode, pump 210 causes the heat-conducting fluid to flow through the battery 112 for heat exchange and then to valve 204. In some examples, such as Figure 2 As shown, valve 204 is a three-way valve controlled by ECM 130. Although valve 204 is depicted as a three-way valve, whereby the valve can direct liquid flow in one of two directions, it should be understood that valve 204 (and valve 208 discussed below) can be implemented in any of the many ways known to those skilled in the art to achieve the same or similar results. Figure 2 As depicted, in the passive thermal mode of BTMS 132, ECM 130 causes valve 204 to further guide the thermal fluid from battery 112 along fluid path 202 to passive core 206.

[0032] In some examples, the passive core 206 is a heat sink or similar heatsink configured to extract heat from a heat-conducting fluid flowing in the fluid path 202. This heat transfer in passive thermal mode may occur partly because the ambient temperature around the passive core 206 is lower than the temperature of the heat-conducting fluid. This heat transfer may also occur partly due to the convective forces generated by the fan 212 blowing across the passive core 206, possibly controlled by the ECM 130. In other cases, when the environment around the passive core 206 is hotter than the fluid, the passive core 206 may transfer heat to the heat-conducting fluid.

[0033] In passive thermal mode, fluid path 202 continues from passive core 206 via valve 208 and pump 210 to battery 112. Valve 208 may be a three-way valve controlled by ECM 130 to direct heat transfer fluid from one of the two sources to pump 210. For example, pump 210 may be an electrically controlled water pump that can operate under the control of ECM 130 to allow heat transfer fluid to flow back to battery 112 at a controlled rate. Additional pumps or similar devices may also be used to assist in the movement of heat transfer fluid through ECM 130.

[0034] The heat transfer that occurs in the passive thermal mode of operation of BTMS 132 typically draws very little energy from battery 112. Essentially, only pump 210 and fan 212 contain motors that require electricity to operate. Therefore, while the thermal efficiency in passive thermal mode may be lower, depending on the temperature difference between the external environment and the heat transfer fluid, its electrical efficiency is higher.

[0035] When operating in active heating mode, BTMS 132 can use a portion of the fluid path 202 between valves 204 and 208, and heating path 222 or cooling path 242, to exchange heat energy between battery 112 and fluid path 202. For active heating, BTMS 132 may include heating path 222 to allow heat-conducting fluid to flow through heating element 220 connected in parallel with battery 112, such as... Figure 2 As shown. Heating element 220 may include a resistance coil or other device for applying heat energy to the heat-conducting fluid received from fluid path 202. Heating path 222 may include expansion tank 224 for absorbing any excess heat-conducting fluid caused by thermal expansion. Therefore, if necessary, such as when sensor 250 detects that the battery cell temperature is below a preset value (and possibly also ambient temperature), ECM 130 may activate heating element 220 to increase the temperature of the heat-conducting liquid, which is then drawn by pump 210 along heating path 222 and through battery 112.

[0036] For active cooling, the BTMS may include a cooling path 242 to allow heat-conducting fluid to flow through the evaporator 240 and in parallel with the battery 112, such as Figure 2 As shown. When ECM 130 determines that active cooling is needed, such as when sensor 250 detects that the battery cell temperature is higher than a preset value (and possibly ambient temperature), ECM 130 can direct valve 204 to guide heat transfer fluid to flow through fluid path 202 and output it on cooling path 242. The heat transfer fluid then flows through evaporator 240. Similarly, ECM 130 can direct valve 208 to guide heat transfer fluid from evaporator 240 to pump 210 via fluid path 202.

[0037] Evaporator 240 (also referred to as a cooler) functions as a heat exchanger that removes heat from the heat-conducting fluid that travels along cooling path 242 and through the evaporator. On the opposite side of evaporator 240, refrigerant path 232 forms a closed loop between compressor 230, condenser 234, dryer 236, expansion valve 238, and evaporator 240. Any suitable type of refrigerant (such as R134a, Freon, hydrofluorocarbons, or any compressible gas or liquid) passes through refrigerant path 232. In a known manner, the refrigerant is compressed by compressor 230, undergoes a change of state in condenser 234, and its flow rate is regulated by expansion valve 238 during the refrigeration cycle. At evaporator 240, thermal energy from the heat-conducting fluid traveling through cooling path 242 is transferred to the refrigerant, thereby lowering the temperature of the heat-conducting fluid in cooling path 242. Therefore, the cooler heat-conducting fluid passes through valve 208 and is drawn through battery 112 by pump 210 to help reduce the battery cell temperature detected by sensor 250.

[0038] Figure 2 Variations of BTMS 132 are within the scope of this disclosure. For example, BTMS 132 may exclude an active cooling portion having refrigerant path 232. In other examples, BTMS 132 may exclude an active heating portion having heating element 220. Furthermore, different arrangements or selections of components for heating and cooling functions are possible and known to those skilled in the art to achieve the objectives described in this disclosure.

[0039] Compared to the passive thermal mode of operation, the amount of energy that can be extracted from the battery 112 during heat transfer in the active thermal mode of operation of the BTMS 132 is significantly greater. In addition to the electrical consumption of the pump 210, heating elements 220 and compressor 230 typically require substantial current, which can degrade the battery SoC. Therefore, while the thermal efficiency may be higher in active thermal mode, the electrical efficiency may be lower, especially compared to passive thermal mode.

[0040] Under certain operating conditions of the machine tool 100, the control system 200 can enable the BTMS 132 to closely align the battery cell temperature with the ideal pre-regulated temperature of the battery 112. However, this operating mode may cause unnecessary consumption of the battery 112. For example, allowing the battery cell temperature to deviate from the pre-regulated temperature due to ambient temperature and / or heat generated by the machine tool 100 would save SoC and extend the operating time of the machine tool 100 during operation. However, when the battery 112 begins to deplete, if high-power fast charging is required, the BTMS 132 needs to bring the battery's operating temperature (i.e., the battery cell temperature) back to (or close to) the pre-regulated temperature of the battery 112 for its highest charging efficiency.

[0041] According to the principles of this disclosure, in the event of anticipated fast charging, the ECM 130 of the control system 200 is programmed or otherwise configured to monitor the state of charge (SoC) of the battery 112, selectively provide notification via the operator interface 106 when the SoC reaches a threshold SoC, and use the BTMS 132 to adjust the battery cell temperature to an ideal or preferred pre-regulated temperature. In this context, "threshold SoC" refers to the state of charge of the battery 112, at which the ECM 130 determines that notification regarding the need for pre-regulation should be provided to the operator if fast charging is expected. As discussed in more detail below, while various factors may be included in determining the threshold SoC used to notify the operator, the threshold SoC will generally take into account the amount of battery charge required for the BTMS 132 to complete the pre-regulation of the battery 112.

[0042] Figure 3An example breakdown of the charge capacity 300 of battery 112 during operation within the working machine 100 is depicted, as a context for discussing the operation of ECM 130 and BTMS 132. Figure 3 In the diagram, the charge capacity of 300 ranges from 100% on the left to 0% on the right. For example... Figure 3 As shown, battery 112 has approximately 80% of its current SoC 302 at the current time. In this example, ECM 130 calculates an expected SoC change 304 of approximately 15% when pre-regulating battery 112. Additionally, consistent with the discussion below, the ECM 130 in this example applies a buffer amount 306 of approximately 30% of full charge. Therefore, in Figure 3 In the example, ECM 130 calculates a threshold SoC 308 of 45% of the charge capacity 300 of battery 112, at which a notification should be provided to operator interface 106.

[0043] In some examples, ECM 130 is configured to determine the expected SoC change 304 of battery 112 under current operating conditions. As discussed above, BTMS 132 may require variable electrical energy from battery 112 to adjust the battery cell temperature. Adjusting the battery cell temperature to equal to or close to the desired pre-regulated temperature may similarly require different levels of energy, and the SoC will decrease accordingly depending on a variety of factors. For example, a larger difference between the current battery cell temperature and the desired pre-regulated temperature will require more energy and may take longer for BTMS 132 to adjust compared to a smaller temperature difference. These temperature differences, as well as the ambient temperature under current operating conditions, may influence ECM 130's decision on whether to implement an active thermal mode or a passive thermal mode for thermal management. The active thermal mode of adjustment by BTMS 132 typically requires significantly more charge from battery 112 than the passive thermal mode.

[0044] Other parameters of battery 112 may also affect the amount of charge (or similarly, the amount of time) pre-regulated. Parameters of the SoH of battery 112 received from sensor 250 can inform ECM 130 of the rate of change of SoC, battery capacity, and battery life. ECM 130 can be programmed to take into account these and similar parameters, which can help indicate the health of the battery cells and their efficiency in providing the charge required for pre-regulation by BTMS 132. For example, if battery 112 is nearing the end of its life and its SoC exhibits a rapid rate of change during the current charging cycle (likely due to operating conditions under current conditions), ECM 130 might calculate a relatively large expected SoC change 304 resulting from pre-regulating battery 112. On the other hand, if battery 112 is new, has not been subjected to heavy loads in the current operating environment, and its SoC exhibits a slow rate of change, ECM 130 might calculate a relatively small expected SoC change 304 resulting from pre-regulating battery 112.

[0045] The capacity and efficiency of BTMS 132 may also affect the calculation or prediction of the expected SoC change 304 caused by pre-conditioning of battery 112 under the current operating conditions of machine 100. If the fluid system within BTMS 132 is large (i.e., the fluid path 202, heating element 220, compressor 230, evaporator 240, etc., have the ability to quickly modify the battery cell temperature), then ECM 130 can conclude that BTMS 132 can quickly achieve the pre-conditioning temperature and requires a correspondingly small change in SoC. Conversely, a BTMS 132 that is too small may take a long time to adjust the battery cell temperature to the pre-conditioning temperature, resulting in a larger expected change in SoC.

[0046] ECM 130 can take these and other factors into account to determine the expected SoC change 304 of battery 112 due to the pre-conditioning process. Depending on the operating machinery, fewer or more factors may be considered to determine how long it takes for the battery cell temperature to reach the pre-conditioning temperature, or similarly, how much charge needs to be consumed. ECM 130 should notify the operator of the pre-conditioning event at least before this amount of time or when this amount of charge remains, to ensure that pre-conditioning can be completed before fast charging should begin.

[0047] In determining the expected SoC change 304 resulting from pre-conditioning of battery 112 under current operating conditions, in some examples, ECM 130 applies a buffer amount 306 to the expected SoC change 304 to obtain a threshold SoC 308. The buffer amount 306 can be derived from various issues and data, and it will provide an additional amount of charge (or time) that should be included when determining the point at which pre-conditioning should be notified to the operator (i.e., the threshold SoC 308). In some examples, the buffer amount 306 includes the amount of charge (or time) that should be allocated to the operator to complete the current work and return to the charging station within the work site. For example, as... Figure 3 As shown, ECM 130 determines to add a buffer amount of 30% of the full SoC of battery 112 to the expected SoC change 304. The combination of the buffer amount 306 and the expected SoC change 304 caused by pre-adjustment will result in a threshold SoC 308, at which the operator should be notified.

[0048] ECM 130 can derive the buffer amount 306 included within the threshold SoC 308 in several ways. For example, the buffer amount 306 can be a fixed and predetermined value, such as 10% of the full SoC of battery 112, or ECM 130 can calculate the buffer amount based on the type and location of the work machinery 100 within the work site. As an example, different types of work machinery can have significantly different ground speeds, such as the physical differences between wheel loaders, excavators, and bulldozers. Therefore, the amount of charge (or time) required for work machinery 100 to travel to the charging station can depend on its characteristics (which ECM 130 can take into account when selecting the buffer amount 306) and its distance from the charging station. Those skilled in the art will understand that ECM 130 can handle these and other factors to determine the appropriate buffer amount to add to the expected drop in SoC caused by pre-conditioning, thus obtaining the threshold SoC 308.

[0049] Following these principles, Figure 4 An exemplary graphical layout 402 within the operator interface 106 is depicted for notifying the operator that pre-adjustment is required in preparation for fast charging. Although for illustrative purposes... Figure 4 While a graphical layout is involved, notifications via operator interface 106 are not limited to the exemplary graphical layout 402. Notifications may be provided in other ways, such as via text messages, sound alarms, haptic feedback, or other forms of sensory communication that can be interpreted by the operator of the operating machinery 100.

[0050] exist Figure 4In the example, the graphical layout 402 includes several icons or graphical displays for conveying the current SoC 302 of battery 112. For example, on the left side of the display, graph 404 indicates, as an example, that the current SoC is 45%. On the right side of the display, icon 406 and text indicate the estimated remaining time before battery 112 is depleted. According to the principles of this disclosure, when a threshold SoC 308 is equal to or exceeds the current SoC 302 of battery 112, a notification 408 appears on operator interface 106 and inquires whether fast charging of battery 112 is required. ECM 130 can be configured to make notification 408 attract the attention of the operator of the operating machinery 100, such as by displaying it in bright colors, large text, or flashing graphics. Additionally or alternatively, ECM 130 may accompany notification 408 with an audible or tactile alarm.

[0051] In the exemplary graphical layout 402, user-selectable Accept 410 (“Yes”) and user-selectable Reject 412 (“No”) are also displayed as keys on the operator interface 106. Although illustrated as soft keys on a touch-sensitive screen, user-selectable Accept 410 and user-selectable Reject 412 can be hard keys, keys activated by a mouse or pointer, or any other implementation for achieving the stated result. The operator of the work machine 100 can respond to notification 408 (“Fast charging required?”) by selecting either of these user-selectable soft keys. If user-selectable Accept 410 is selected, ECM 130 commands BTMS 132 to adjust the battery cell temperature of battery 112 to the battery’s pre-adjusted temperature. If user-selectable Reject 412 is pressed, ECM 130 will not initiate pre-adjustment and will generally continue to control the work machine according to its existing parameters.

[0052] In some examples, the ECM 130 is configured to start a timer (not shown) when the operator interface 106 displays notification 408. This timer can be set to a predetermined value, providing the operator with a time period to respond to the notification. In some examples, if neither the user-selectable accept 410 nor the user-selectable reject 412 is selected before the timer expires, the control system 200 using the ECM 130 will begin pre-conditioning the battery. The operator may be busy operating the work machinery 100 and unable to notice or respond to notification 408. Initiating the pre-conditioning process after a short delay in the absence of a response ensures that the work machinery 100 is ready to accept fast charging by default, allowing the machinery to continue its operation without having to stop for slow charging. The timer can be any tool available to the ECM 130 for measuring time, including positive timers, countdown timers, setpoints triggered by events following the initiation of notification 408, and other techniques known to those skilled in the art.

[0053] If the control system 200 receives a response from the user-selectable rejection 412, the ECM 130 can control the BTMS 132 to regulate the battery cell temperature in either an active or passive thermal mode based on the current operating conditions of the machine 100, such as ambient temperature and the energy demand of the battery 112. In some examples, rejection of fast charging indicates that the operator is nearing the end of the workday, and therefore slow charging at low power for an extended period is acceptable. By operating in passive thermal mode according to the current operating conditions, the BTMS 132 can conserve remaining battery charge, or at least avoid unnecessarily using that charge to regulate the battery cell temperature, and accordingly preserve battery charge and provide the machine 100 with a longer operating time than if it were ready for fast charging.

[0054] from Figures 1 to 4 The structure and operation of the illustrated machine 100 relate to the method of the system. Figure 5 This is a flowchart of a representative method for controlling battery pre-conditioning in operating machinery. Example process 500 is illustrated as a set of steps in a logic flowchart, representing the operations that can be performed when battery pre-conditioning is initiated. The order in which the operations are described is not intended to be construed as limiting, and the process can be implemented by combining and performing any number of the described steps in any order, in parallel, or simultaneously.

[0055] Overall, it is reflected as Figure 5 In step 500, the method begins at step 502 and proceeds to step 504, which involves receiving sensor data, during the operation of the working machine 100. (As mentioned above...) Figure 2 and Figure 3 As explained, the control system 200 within the work machinery 100 may include an ECM 130 configured to receive data from one or more sensors 250 arranged throughout the machinery (including within the BTMS 132). The sensor data may include information relating to the SoC or SoH of the battery 112, various temperatures at components and within fluids in the BTMS 132, and other physical parameters of the work machinery 100.

[0056] In step 506, the threshold SoC is determined. For example... Figure 2 and Figure 3As illustrated and discussed above, for example, ECM 130 calculates or determines a threshold SoC 308 related to the operating machinery 100 based on data received from sensor 250, at which an alarm or notification should be provided to the machinery operator. For example, ECM 130 can evaluate data such as the SoC and SoH of battery 112, the type of operating machinery 100, the rate of change of SoC, the size or capacity of BTMS 132, the size and usage time of battery 112, and other factors to predict the expected change 304 of SoC caused by adjusting the battery cell temperature to equal the battery's high-efficiency charging temperature or pre-conditioning temperature. Furthermore, ECM 130 can access from memory or otherwise determine the amount of charge (or time) buffer 306 to be added to the expected change 304 of SoC to obtain the threshold SoC 308, at which an alarm or notification should be provided.

[0057] In step 508, the SoC is compared with a threshold SoC. Specifically, ECM 130 can be programmed to determine whether the current SoC 302 of battery 112 is less than or equal to the calculated threshold SoC 308. If not, process 500 returns to step 504, and ECM 130 continues to receive data from sensor 250. If the current SoC 302 is less than or equal to the threshold SoC 308, ECM 130 will present an alarm or notification to the operator of the operating machinery 100 (step 510), such as displaying it on operator interface 106. As discussed above, the notification provides information on operator interface 106 about, for example, the SoC of battery 112, and provides an inquiry about whether fast charging is required. The notification may also include an arrangement for the operator to answer the inquiry (e.g., by inputting a user-selectable accept 410 (“Yes”) and a user-selectable reject 412 (“No”). Simultaneously with the notification, ECM 130 will start a timer (step 512). The timer can be any type of time counter; in some examples, the timer will track the passage of several minutes.

[0058] During the timer count, process 500 will wait for a response to an alarm or notification (step 514). If no response is received, the process will continue to monitor the timer and evaluate any feedback from the operator (step 516). If a response to the notification is received, in step 518, the process determines whether the response is an acceptance or rejection of fast charging. If the response is a rejection, perhaps because the operator's work is nearing completion and there is time for slow charging, the process will proceed to end 522 and stop. However, if the response is an acceptance, perhaps because the operator has more work to do with the machine and desires fast charging, process 500 will proceed to step 520, where battery pre-conditioning will begin. Similarly, if no response to the notification is received (step 514) and the timer has expired (step 516), control system 200 will begin battery pre-conditioning in the same manner (step 520).

[0059] As discussed in detail above, in step 520, the control system 200 will cause the BTMS 132 to adjust the battery cell temperature to equal the pre-adjustment temperature, which may involve invoking an active thermal mode within the BTMS 132. During the pre-adjustment period, the BTMS 132 will draw current from the battery 112 as predicted, and the buffer 306 will retain sufficient charge to power the operating machinery 100 once the pre-adjustment temperature is reached.

[0060] Those skilled in the art will understand that the principles of this disclosure are not limited to the specific examples discussed or illustrated in the figures. For example, while battery pre-conditioning has been discussed in the context of battery-electric machinery, similar but different steps can be followed to apply the disclosed principles to machinery including other power sources, such as battery-electric vehicles, hybrid vehicles, or any other mobile machinery at least partially powered by batteries. Additionally, while the discussion pertains to work machinery manually operated from within the operator's cab 104, notification can be provided to an operator module outside the work machinery 100 during autonomous or semi-autonomous operation. Furthermore, in addition to the factors listed above, other factors may be included to evaluate and determine the expected changes 304 and buffer amounts 306 of the SoC within the threshold SoC 308 without departing from the intended purpose of the disclosed system.

[0061] Industrial applicability This disclosure provides a battery-powered work machine with a control system for determining a threshold state of charge (SOC) of the battery and requesting an instruction from the operator whether to pre-condition the battery for fast charging. The control system evaluates various current parameters in the machine, such as battery cell temperature, ambient temperature, battery health, battery size, and the capacity of the battery thermal management system, to determine the expected change in SOC caused by pre-conditioning the battery. A buffer amount of charge is added to define the threshold SOC. When the threshold exceeds the battery's current SOC, the control system provides a notification via an operator interface, allowing the operator to choose or reject fast charging for battery pre-conditioning.

[0062] As mentioned above Figures 1 to 5 The pointed-out operating machinery (such as) Figure 1 The system 100 includes a battery 112 serving as a power source and a BTMS 132 configured to regulate battery temperature under different conditions. The control system 200 includes an ECM 130, sensors 250, and an operator interface 106, arranged to control the battery cell temperature in different thermal modes according to varying battery charging needs. Under the current operating conditions of the machine 100, the ECM 130 evaluates various data from the sensors 250, predicts the expected decrease in SoC caused by pre-regulating the battery, and determines a threshold SoC 308 after including buffered charge. When the current SoC 302 is equal to or below the threshold SoC 308, the ECM 130 displays a notification on the operator interface regarding the possibility of fast charging. If the operator accepts, or if the operator does not respond after a predetermined time, the control system instructs the BTMS 132 to adjust the battery cell temperature to equal the pre-regulated temperature of the battery. The BTMS may employ an active thermal mode in which a large amount of charge is drawn from the battery, as envisioned by the threshold SoC 308. If the operator refuses fast charging, the control system will continue in its normal operating mode, which may limit the BTMS to passive thermal mode to conserve the remaining battery charge.

[0063] In the examples disclosed herein, the control system within the battery-powered work machinery provides a prediction of the amount of charge required to pre-regulate the battery under conditions suitable for the machinery's current operating conditions, enabling an alert to the operator to maintain sufficient charge. When more work needs to be completed, timely notification via the operator interface allows for prompt initiation of pre-regulation using an active thermal mode for rapid charging. Conversely, if slow charging is sufficient and selected by the operator, a passive thermal mode can be used to extend battery life and runtime. Traditional passenger vehicle pre-regulation standards, such as driving speed and distance determined by navigation systems, are not required.

[0064] Unless explicitly excluded, the use of the singular to describe a component, structure, or operation does not preclude the use of multiple such components, structures, operations, or their equivalents. As used herein, the word "or" refers to any possible permutation of a set of items. For example, the phrase "A, B, or C" refers to at least one of A, B, or C, or any combination thereof, such as A; B; C; A and B; A and C; B and C; A, B, and C; or multiples of any item, such as A and A; B, B, and C; A, A, B, C, and C, etc.

[0065] Approximate terms are intended to include a range of values ​​for a function or result that does not change the disclosed structure or process. For example, the term “approximately” generally refers to a range of values ​​that a person skilled in the art would consider equivalent to or have the same function or result as the stated value. Similarly, the antecedent “substantially” largely (but not entirely) means the same form, manner, or degree, and that a particular element will have a range of configurations that a person skilled in the art would consider to have the same function or result.

[0066] While various aspects of this disclosure have been specifically shown and described with reference to the foregoing examples, those skilled in the art will understand that various additional examples can be conceived by modifying the disclosed systems and methods without departing from the spirit and scope of the disclosure. Such examples should be understood to fall within the scope of this disclosure as defined by the claims and any equivalents.

Claims

1. A control system within a work machine, the control system comprising: A battery configured to power the operating machinery, the battery having a state of charge (SoC) and a cell temperature; A battery thermal management system (BTMS) configured to regulate the temperature of the battery cells using either an active thermal mode or a passive thermal mode; Operator interface; and Electronic controller, the electronic controller being configured to: Calculate the expected decrease in the SoC caused by the BTMS adjusting the battery cell temperature to the pre-adjusted temperature under the current operating conditions of the machine. A threshold SoC is determined based at least in part on the expected decrease of the SoC, and a notification related to pre-regulating the battery is communicated at the threshold SoC. Once the SoC equals the threshold SoC, the notification is communicated through the operator interface; The operator interface receives a response to the notification, the response including a request for fast charging or a rejection of fast charging; as well as Based on the response, the BTMS is instructed to use either the active thermal mode or the passive thermal mode to adjust the battery cell temperature.

2. The control system according to claim 1, wherein the current operating conditions include battery cell temperature, ambient temperature, and battery capacity.

3. The control system according to claim 2, wherein the current operating conditions include the capacity of the BTMS and the rate of change of the SoC.

4. The control system according to claim 2, wherein the electronic controller is further configured to: Upon receiving the request for fast charging, the BTMS is instructed to use the active thermal mode to adjust the battery cell temperature to the pre-adjusted temperature.

5. The control system according to claim 1, wherein the electronic controller is further configured to: Upon receiving the rejection of the fast charging, based on the current operating conditions of the control system, the BTMS is instructed to use either the active thermal mode or the passive thermal mode to regulate the battery cell temperature.

6. The control system of claim 1, wherein the electronic controller is further configured to: When the notification is communicated through the operator interface, a timer is activated at a predetermined time; and If no response is received within the predetermined time after the notification, the battery cell temperature is adjusted to the pre-adjusted temperature.

7. The control system of claim 1, wherein determining the threshold SoC includes adding at least one buffer amount to the expected decrease of the SoC, the buffer amount being an amount of charge sufficient to allow the working machine to complete its work and move to the charging station.

8. A computer-implemented method, the method comprising: The electronic controller receives data related to the current operating conditions of the battery-powered machinery, including the ambient temperature and the battery cell temperature. The electronic controller calculates the expected decrease in the state of charge (SoC) of the battery caused by the battery thermal management system (BTMS) adjusting the battery cell temperature to a pre-regulated temperature under the current operating conditions. A threshold SoC is determined based at least in part on the expected decrease of the SoC, and a notification related to pre-regulating the battery is provided at the threshold SoC; Compare the SoC with the threshold SoC; Once the SoC equals the threshold SoC, the notification is communicated through the operator interface; Receive responses related to the notification through the operator interface; as well as In response to the response, the BTMS is instructed to adjust the temperature of the battery cell.

9. The computer-implemented method according to claim 8, further comprising: The operator interface displays a first user-selectable input corresponding to a request for fast charging and a second user-selectable input corresponding to a rejection of fast charging.

10. The computer-implemented method of claim 9, wherein the response is the request for fast charging, and the instruction of the BTMS comprises: The BTMS is instructed to adjust the temperature of the battery cell to the pre-adjusted temperature.

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