Detection and remediation of liquid intrusion in vehicle battery packs

Abstract

Detection and remediation of liquid intrusion in a vehicle battery pack. A system includes a battery pack, a sensor configured to sense an intermediate assembly voltage of the battery pack, and a control module. The control module is configured to determine an isolation resistance of the battery pack based on the intermediate assembly voltage, monitor a characteristic associated with the battery pack and indicative of liquid intrusion inside the battery pack, set one or more flags based on the monitored characteristic, identify a severity level of a plurality of severity levels of liquid intrusion inside the battery pack based on which one or more characteristics caused the one or more flags to be set, and select at least one remediation measure of a plurality of remediation measures for remediation of the liquid intrusion inside the battery pack in response to the identified severity level. Other example systems and methods are also disclosed.

Description

[0001] introduction

[0002] The information provided in this section is for the purpose of presenting the overall context of this disclosure. To the extent described in this section, the work of the currently named inventors, and aspects that may not otherwise conform to the description as prior art at the time of submission, are neither explicitly nor implicitly acknowledged as prior art contrary to this disclosure.

[0003] This disclosure relates to the detection and remedy of liquid intrusion in vehicle battery packs.

[0004] Electric vehicles, such as battery electric vehicles, hybrid electric vehicles, and / or fuel cell vehicles, include one or more motors and a battery system having one or more battery cells, modules, and / or battery packs. For example, a battery system may be a rechargeable energy storage system comprising one or more high-voltage battery packs, each high-voltage battery pack having an assembly of battery cells. Typically, one or more battery packs in a rechargeable energy storage system are electrically isolated from components outside the battery packs. Summary of the Invention

[0005] A system for detecting and remediating liquid intrusion inside a vehicle battery pack includes: a battery pack comprising a plurality of battery cells; a sensor configured to sense a midpack voltage of the battery pack; and a control module in communication with one or more sensors. The control module is configured to: determine an isolation resistance of the battery pack based on the midpack voltage; monitor characteristics associated with the battery pack and indicating liquid intrusion inside the battery pack, including a current value of the isolation resistance, the behavior of the midpack voltage over time, and the behavior of the isolation resistance over time; set one or more flags based on the monitored characteristics; identify a severity level among a plurality of severity levels of liquid intrusion inside the battery pack based on which of the one or more characteristics causes the one or more flags to be set; and, in response to the identified severity level, select at least one of a plurality of remedial measures to remedy the liquid intrusion inside the battery pack.

[0006] Among other features, the control module is configured to generate control signals for implementing at least one selected remedy.

[0007] Among other features, the severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe compared to the first severity level.

[0008] Among other features, the control module is configured to identify the first severity level of liquid intrusion inside the battery pack when the current value of the isolation resistance is less than a defined threshold.

[0009] Among other features, the plurality of remedial measures includes a set of emergency remedial measures and a set of non-emergency remedial measures, and the control module is configured to select at least one of the emergency remedial measures in response to identifying the first severity level.

[0010] Among other features, the group of emergency remedies includes changing the battery pack charging control settings, changing the vehicle's chiller control settings, changing the vehicle's power limit settings, changing the coolant pump control settings, setting diagnostic fault codes (DTCs), and providing emergency driver notification.

[0011] Among other features, the control module is configured to identify the second severity level of liquid intrusion inside the battery pack based on the change of intermediate component voltage over time and a first threshold or the change of isolation resistance over time and a second threshold.

[0012] Among other features, multiple remedial measures include a set of emergency remedial measures and a set of non-emergency remedial measures. The control module is configured to select at least one non-emergency remedial measure in response to identifying a second severity level. The set of non-emergency remedial measures includes changing the state-of-charge limit of the battery pack, changing the power limit setting of the vehicle, setting a diagnostic fault code (DTC), and providing a driver notification.

[0013] Among other features, multiple severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe compared to the first severity level, one or more flags include at least a first flag set based on the current value of the isolation resistance and a second flag set based on the behavior of the intermediate component voltage over time or the behavior of the isolation resistance over time, and the identified severity level is the first severity level.

[0014] Among other features, multiple severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe than the first severity level, one or more flags include at least a first flag based on the behavior of intermediate component voltage over time and a second flag based on the behavior of isolation resistance over time, and the identified severity level is the second severity level.

[0015] A method for detecting and remediating liquid intrusion within a vehicle's battery pack includes: receiving an intermediate component voltage of the battery pack from a voltage sensor; determining an isolation resistance of the battery pack based on the intermediate component voltage; monitoring characteristics associated with the battery pack and indicating liquid intrusion within the battery pack, the characteristics including a current value of the isolation resistance, the behavior of the intermediate component voltage over time, and the behavior of the isolation resistance over time; setting one or more flags based on the monitored characteristics; identifying a severity level among a plurality of severity levels of liquid intrusion within the battery pack based on which one or more characteristics cause the setting of the one or more flags; and selecting at least one of a plurality of remedial measures to remedy the liquid intrusion within the battery pack in response to the identified severity level.

[0016] Among other features, the method also includes generating control signals for implementing at least one selected remedy.

[0017] Among other features, multiple severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe compared to the first severity level; one or more flags include at least a first flag set based on the current value of the isolation resistance and a second flag set based on the behavior of the intermediate component voltage over time or the behavior of the isolation resistance over time; and identifying the severity level of liquid intrusion inside the battery pack includes identifying the first severity level.

[0018] Among other features, the plurality of severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe than the first severity level, the one or more flags include at least a first flag based on the behavior of intermediate component voltage over time and a second flag based on the behavior of isolation resistance over time, and identifying the severity level of liquid intrusion inside the battery pack includes identifying the second severity level.

[0019] Among the other features, the multiple severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe than the first severity level, and the multiple remedial measures include a set of emergency remedial measures and a set of non-emergency remedial measures.

[0020] Among other features, identifying the severity level of liquid intrusion inside the battery pack includes identifying a first severity level when the current value of the isolation resistance is less than a defined threshold, selecting at least one remedy includes selecting at least one emergency remedy in response to identifying the first severity level, and the set of emergency remedies includes changing the battery pack charging control settings, changing the vehicle's cooler control settings, changing the vehicle's power limit settings, changing the coolant pump control settings, setting a diagnostic fault code (DTC), and providing an emergency driver notification.

[0021] Among other features, identifying the severity level of liquid intrusion inside the battery pack includes identifying a second severity level based on changes in intermediate component voltage over time and changes in a first threshold or isolation resistance over time and a second threshold, and selecting at least one remedy includes selecting at least one non-emergency remedy in response to identifying the second severity level.

[0022] Among other features, this group of non-emergency remedies includes changing the battery pack's state of charge limits, changing the vehicle's power limit settings, setting diagnostic fault codes (DTCs), and providing driver notifications.

[0023] A non-transitory computer-readable medium including instructions, when executed by a control module, the instructions being configured to detect and remedy liquid intrusion inside a vehicle's battery pack by: determining the isolation resistance of the battery pack based on a sensed intermediate component voltage; monitoring characteristics associated with the battery pack and indicating liquid intrusion inside the battery pack, the characteristics including a current value of the isolation resistance, the behavior of the intermediate component voltage over time, and the behavior of the isolation resistance over time; setting one or more flags based on the monitored characteristics; identifying a severity level among multiple severity levels of liquid intrusion inside the battery pack based on which one or more characteristics cause the setting of the one or more flags; and selecting at least one of multiple remedies to remedy the liquid intrusion inside the battery pack in response to the identified severity level.

[0024] Among other features, the non-transitory computer-readable medium includes instructions for generating control signals for implementing at least one selected remedy.

[0025] This invention also includes the following technical solutions:

[0026] Option 1. A system for detecting and remediating liquid intrusion inside a vehicle's battery pack, the system comprising:

[0027] A battery pack that includes multiple battery cells;

[0028] The sensor is configured to sense the voltage of intermediate components in the battery pack; and

[0029] A control module that communicates with the one or more sensors, the control module being configured to:

[0030] The isolation resistance of the battery pack is determined based on the voltage of the intermediate components.

[0031] Monitor characteristics associated with the battery pack and indicate liquid intrusion inside the battery pack, including the current value of the isolation resistance, the behavior of intermediate component voltage over time, and the behavior of the isolation resistance over time;

[0032] Set one or more flags based on the monitored characteristics;

[0033] Based on which one or more of the aforementioned characteristics cause the one or more flags to be set, identify the severity level among multiple severity levels of liquid intrusion into the battery pack; and

[0034] In response to the identified severity level, at least one of a plurality of remedial measures is selected to remedy liquid intrusion inside the battery pack.

[0035] Option 2. The system according to Option 1, wherein the control module is configured to generate a control signal for implementing the at least one selected remedial measure.

[0036] Option 3. The system according to Option 1, wherein the plurality of severity levels includes a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe than the first severity level.

[0037] Option 4. The system according to Option 3, wherein the control module is configured to identify a first severity level of liquid intrusion inside the battery pack when the current value of the isolation resistor is less than a defined threshold.

[0038] Option 5. The system according to Option 4, wherein:

[0039] Multiple remedial measures include a set of emergency remedial measures and a set of non-emergency remedial measures; and

[0040] The control module is configured to select at least one of the emergency remedies in response to identifying the first severity level.

[0041] Option 6. The system according to Option 5, wherein the group of emergency remedial measures includes changing the battery pack charging control settings, changing the vehicle cooler control settings, changing the vehicle power limit settings, changing the coolant pump control settings, setting diagnostic fault codes (DTCs), and providing emergency driver notification.

[0042] Option 7. The system according to Option 3, wherein the control module is configured to identify a second severity level of liquid intrusion inside the battery pack based on the change of the intermediate component voltage over time and a first threshold or the change of the isolation resistance over time and a second threshold.

[0043] Option 8. The system according to Option 7, wherein:

[0044] Multiple remedial measures include a set of emergency remedial measures and a set of non-emergency remedial measures;

[0045] The control module is configured to select at least one non-emergency remedy in response to identifying a second severity level; and

[0046] This group of non-emergency remedies includes changing the battery pack's state of charge limits, changing the vehicle's power limit settings, setting diagnostic fault codes (DTCs), and providing driver notification.

[0047] Option 9. The system according to Option 1, wherein:

[0048] The plurality of severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe compared to the first severity level;

[0049] The one or more flags include at least a first flag set based on the current value of the isolation resistance and a second flag set based on the behavior of the intermediate component voltage over time or the behavior of the isolation resistance over time; and

[0050] The severity level identified is Level 1.

[0051] Option 10. The system according to Option 1, wherein:

[0052] The plurality of severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe compared to the first severity level;

[0053] The one or more flags include at least a first flag set based on the behavior of the intermediate component voltage over time and a second flag set based on the behavior of the isolation resistance over time; and

[0054] The severity level identified is level two.

[0055] Option 11. A method for detecting and remediating liquid intrusion inside a vehicle's battery pack, the method comprising:

[0056] Receive the intermediate component voltage of the battery pack from the voltage sensor;

[0057] The isolation resistance of the battery pack is determined based on the voltage of the intermediate components.

[0058] Monitor characteristics associated with the battery pack and indicate liquid intrusion inside the battery pack, including the current value of the isolation resistance, the behavior of intermediate component voltage over time, and the behavior of the isolation resistance over time;

[0059] Set one or more flags based on the monitored characteristics;

[0060] Based on which one or more characteristics cause the one or more flags to be set, identify the severity level among multiple severity levels of liquid intrusion into the battery pack; and

[0061] In response to the identified severity level, at least one of a plurality of remedial measures is selected to remedy liquid intrusion inside the battery pack.

[0062] Option 12. The method according to Option 11 further includes generating a control signal for implementing the at least one selected remedy.

[0063] Option 13. The method according to Option 12, wherein:

[0064] The plurality of severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe compared to the first severity level;

[0065] The one or more flags include at least a first flag set based on the current value of the isolation resistance and a second flag set based on the behavior of the intermediate component voltage over time or the behavior of the isolation resistance over time; and

[0066] Identifying the severity level of liquid intrusion inside the battery pack includes identifying the first severity level.

[0067] Option 14. The method according to Option 12, wherein:

[0068] The plurality of severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe compared to the first severity level;

[0069] The one or more flags include at least a first flag set based on the behavior of the intermediate component voltage over time and a second flag set based on the behavior of the isolation resistance over time; and

[0070] Identifying the severity level of liquid intrusion inside the battery pack includes identifying the second severity level.

[0071] Option 15. The method according to Option 11, wherein:

[0072] The plurality of severity levels includes a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a less severe state of liquid intrusion compared to the first severity level; and

[0073] Multiple remedial measures include a set of emergency remedial measures and a set of non-emergency remedial measures.

[0074] Option 16. The method according to Option 15, wherein:

[0075] Identifying the severity level of liquid intrusion inside the battery pack includes identifying the first severity level when the current value of the isolation resistance is less than a defined threshold;

[0076] Selecting at least one remedy includes selecting at least one emergency remedy in response to identifying the first severity level; and

[0077] The emergency remedial measures include changing the battery pack charging control settings, changing the vehicle's cooler control settings, changing the vehicle's power limit settings, changing the coolant pump control settings, setting diagnostic fault codes (DTCs), and providing emergency driver notification.

[0078] Option 17. The method according to Option 15, wherein:

[0079] Identifying the severity level of liquid intrusion within the battery pack includes identifying a second severity level based on changes in intermediate component voltage over time and a first threshold, or changes in isolation resistance over time and a second threshold; and

[0080] Selecting at least one remedy includes selecting at least one non-emergency remedy in response to identifying a second severity level.

[0081] Option 18. The method according to Option 17, wherein the group of non-emergency remedies includes changing the state of charge limit of the battery pack, changing the power limit setting of the vehicle, setting a diagnostic fault code (DTC), and providing driver notification.

[0082] Option 19. A non-transitory computer-readable medium comprising instructions, which, when executed by a control module, are configured to detect and remedy liquid intrusion inside a vehicle battery pack by:

[0083] The isolation resistance of the battery pack is determined based on the sensed intermediate component voltage;

[0084] Monitor characteristics associated with the battery pack and indicate liquid intrusion inside the battery pack, including the current value of the isolation resistance, the behavior of intermediate component voltage over time, and the behavior of the isolation resistance over time;

[0085] Set one or more flags based on the monitored characteristics;

[0086] Based on which one or more characteristics cause the one or more flags to be set, identify the severity level among multiple severity levels of liquid intrusion into the battery pack; and

[0087] In response to the identified severity level, at least one of a plurality of remedial measures is selected to remedy liquid intrusion inside the battery pack.

[0088] Option 20. The non-transitory computer-readable medium according to Option 19 further includes instructions for generating control signals for implementing the at least one selected remedy.

[0089] Further applications of this disclosure will become apparent from the detailed description, claims, and accompanying drawings. The detailed description and specific examples are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0090] This disclosure will become more fully understood based on the detailed description and accompanying drawings, wherein:

[0091] Figure 1 This is a block diagram of an example system for detecting and remediating liquid intrusion inside a battery pack, according to the present disclosure.

[0092] Figure 2 It is based on the provisions of this disclosure, including Figure 1 The system is part of the vehicles;

[0093] Figure 3 Based on this disclosure Figure 1 A block diagram of an example battery pack for the system;

[0094] Figure 4 Based on this disclosure Figure 3 A block diagram of an example cell group in the battery pack;

[0095] Figure 5 This is a block diagram of another example system for detecting and remediating liquid intrusion inside a battery pack, according to this disclosure; and

[0096] Figure 6-7 This is a flowchart of an example control process for detecting and remediating liquid intrusion inside a battery pack, according to this disclosure.

[0097] In the accompanying drawings, reference numerals may be used repeatedly to identify similar and / or identical elements. Detailed Implementation

[0098] Electric vehicles (EVs), such as battery electric vehicles, hybrid electric vehicles, and / or fuel cell vehicles, typically rely on a rechargeable energy storage system (RESS) to store and supply electricity to propel the vehicle. In such examples, an RESS comprises one or more high-voltage battery packs, each containing an assembly of battery cells. In some examples, the battery cells may reside within modules within each battery pack. Within the RESS, one or more battery packs are electrically isolated from external components (e.g., the vehicle's chassis). Using this configuration, the RESS or its components are coupled to high-voltage components, but not grounded to, for example, the vehicle's chassis. In other words, the RESS or its components are electrically isolated from the vehicle's chassis.

[0099] Sometimes, conditions leading to isolation loss can occur in the RESS and / or other high-voltage components, such as liquid intrusion within the high-voltage battery pack. In such examples, the liquid can include water, coolant, electrolyte, etc. In some examples, vehicle diagnostic monitors can detect shock hazards by focusing on isolation loss (e.g., a decrease in isolation resistance). However, such techniques are generally inefficient in detecting and remediating liquid intrusion within the high-voltage battery pack. For example, while a shock hazard can be detected by a vehicle diagnostic monitor, the detection occurs late and / or without prior warning, and does not trigger remedial measures to mitigate the problem. Furthermore, conventional vehicle diagnostic monitors operate only at a single threshold and do not offer any upgrades based on the severity of the risk.

[0100] The system and method disclosed herein provide a solution for detecting liquid intrusion in the high-voltage battery pack of an EV from the perspective of thermal runaway, and for taking appropriate remedial measures based on the detection. For example, the system and method can monitor changes in various sensors / indicators (e.g., voltage sensor values, communication failures, thermal management system behavior, etc.), set one or more flags based on the monitored changes in indicators of liquid detection in the high-voltage battery pack or other indicators of liquid, and then perform sensor fusion to identify or otherwise estimate the severity level. Based on the severity level, appropriate remedial measures can then be taken to mitigate the effects of the liquid intrusion. Using this method, the detection of liquid intrusion in the high-voltage battery pack can occur long before conventional vehicle diagnostic monitors detect a shock hazard (e.g., up to two weeks in advance). This, in turn, provides ample time to take appropriate remedial measures and / or replace the battery pack (if necessary), thereby mitigating the risk of serious fire and / or electric shock hazards caused by liquid intrusion. Therefore, the safety of the vehicle and its occupants (e.g., driver, passengers, bystanders, etc.) is enhanced. Furthermore, the implementation of this method can utilize existing vehicle sensors / indicators, and thus significantly minimizes hardware and vehicle production costs. Furthermore, compared to traditional vehicle diagnostic monitors, this method allows for the monitoring and detection of liquids that are not limited to specific parts of the RESS, and can even detect liquids that are moving around the battery pack as the vehicle moves.

[0101] Now for reference Figure 1 A block diagram of an example system 100 for detecting and remediating liquid intrusion inside a battery pack is presented. Figure 1 As shown, system 100 typically includes a battery pack 102, one or more voltage sensors 104 for sensing one or more voltages of the battery pack 102, and a control module 106. In various embodiments, system 100 may further include one or more additional sensors 108, a display module 110, a vehicle control module 112, a battery charging control module 114, and a cooler control module 116.

[0102] Although Figure 1System 100 is illustrated as including specific dedicated modules; however, it should be understood that one or more other modules may be used if desired. For example, any combination and / or functionality of modules (e.g., control module 106, display module 110, vehicle control module 112, battery charging control module 114, cooler control module 116, etc.) may be integrated into a single module or multiple different modules. Furthermore, although system 100 is shown as including a battery pack 102, it should be understood that system 100 may include multiple battery packs. Regardless of the number of battery packs in system 100, a single battery pack or multiple battery packs may be part of the RESS.

[0103] In various embodiments, the modules and sensors of system 100 can communicate with each other and share parameters via a network, such as a controller area network (CAN). In such an example, parameters can be shared via one or more data buses of the network. Thus, various parameters can be made available to other modules and / or sensors by a given module and / or sensor via the network.

[0104] Figure 1 System 100 can be employed in any suitable implementation in which one or more high-voltage battery packs are incorporated. For example, system 100 can be employed in a vehicle implementation or a non-vehicle implementation. Furthermore, if system 100 can be employed in a vehicle implementation, then system 100 can be located within a vehicle. Regarding a vehicle implementation, system 100 can be part of any suitable vehicle having a RESS comprising one or more high-voltage battery packs for storing and supplying electricity to propel the vehicle. In such an example, the vehicle can be an electric vehicle, such as a pure electric vehicle, a hybrid electric vehicle, etc. Furthermore, system 100 can be adapted to autonomous vehicles, semi-autonomous vehicles, etc. As an example, Figure 2 Depicting including Figure 1 Battery pack 102, (multiple) sensors 204 and Figure 1 The control module 106 of the vehicle 200. In this example, (multiple) sensors 204 may include Figure 1 Any one or more of the sensors 104 and 108.

[0105] Continue to refer to Figure 1 Battery pack 102 typically includes multiple battery cells. In such an example, each battery cell may be able to store and supply electrical energy. In various embodiments, the defined set of battery cells may form a cell group or cell module, wherein each may be selectively removed or replaced with another cell group. For example, Figure 3 Depicting Figure 1 An example of battery pack 102. Figure 3As shown, the battery pack 102 includes a battery housing 340, cell groups (typically indicated by 350) located within the battery housing 340, and battery leads 352, 354 coupled to the cell groups. In such an example, the cell groups include any suitable number of cell groups. For example, in Figure 3 In this embodiment, battery pack 102 includes four cell groups 350-1, 350-2, 350-3, and 350-4. In other examples, battery pack 102 may include one cell group, two cell groups, five cell groups, ten cell groups, sixteen cell groups, twenty-four cell groups, etc. Regardless of the number of cell groups, battery leads 352 and 354 electrically connect battery pack 102 (e.g., cell groups 350-1, 350-2, 350-3, and 350-4) to an output (e.g., a load), an input (e.g., a power source), etc.

[0106] In various embodiments, Figure 1 The battery pack 102 may include battery cells or groups of cells coupled in series and / or parallel configurations to obtain different high voltages. For example, battery cells and / or groups of cells may be coupled in a manner that provides high voltages, such as suitable voltages exceeding 50 volts (e.g., 100 volts, 400 volts, 800 volts, etc.). Figure 2 As shown, unit groups 350-1, 350-2, 350-3, and 350-4 are coupled in series.

[0107] Furthermore, in some examples, the battery cells in any of the cell groups can have a series and / or parallel configuration. For example, Figure 4 Depicting Figure 3 An example of unit group 350-1. For example... Figure 4 As shown, unit group 350-1 includes a housing 440, battery cells (typically indicated by 460) located within the housing 440, and leads 462, 464 coupled to the battery cells. In this example, unit group 350-1 includes three battery cells 460-1, 460-2, and 460-3 coupled in parallel. In other examples, unit group 350-1 may include more or fewer battery cells coupled in series, series / parallel configurations, etc. (e.g., two battery cells, eight battery cells, twelve battery cells, thirty-six battery cells, forty-eight battery cells, ninety-six battery cells, etc.). Figure 4 In the example, lead 462 can be equivalent to Figure 3 Battery lead 352, and lead 464 can be coupled to Figure 3 Unit group 350-2.

[0108] exist Figure 1In this example, the voltage sensors 104 can be any suitable type of sensor for detecting voltages associated with the battery pack 102. For example, the voltage sensors 104 can sense the output voltage of the battery cells in the battery pack 102 (e.g., pack voltage), the negative intermediate component voltage of the battery pack 102, and / or the positive intermediate component voltage of the battery pack 102. In such an example, the control module 106 (or another suitable control module) can cycle the disconnect switch to sense the negative intermediate component voltage and / or the positive intermediate component voltage. For example, the negative intermediate component voltage can be... Figure 2 The chassis voltage in vehicle 200 is represented by the voltage between the negative rail and chassis ground. In this example, multiple voltage sensors 104 may provide control module 106 with one or more signals (e.g., voltage signals) representing the voltage value of battery pack 102. In various embodiments, multiple voltage sensors 104 may be a voltage divider comprising multiple resistors and / or another suitable type of sensor.

[0109] Continue to refer to Figure 1 From a thermal runaway perspective, control module 106 can typically detect liquid intrusion into battery pack 102 and take appropriate remedial measures based on the detection. For example, and as further explained below, control module 106 can utilize various indicators, such as chassis voltage indicators, communication loss indicators, and thermal management indicators, to detect liquid in battery pack 102. Control module 106 can then monitor the indicators (e.g., inputs provided by sensors, etc.) to generate fault signs and estimate the severity of system 100. Based on the severity, control module 106 can then generate different customer-oriented remedial measures (e.g., long-term, non-emergency remedial measures, or emergency remedial measures).

[0110] In particular, Figure 1 In this context, the control module 106 typically monitors various indicators of liquid intrusion within the battery pack 102. For example, and such as Figure 1 As shown, the control module 106 can receive intermediate component voltage (e.g., negative intermediate component voltage, etc.) and the output voltage of the battery pack 102 from (multiple) voltage sensors 104. The control module 106 can then determine the isolation resistance of the battery pack 102 based on the received intermediate component voltage and the output voltage.

[0111] exist Figure 1In the example, intermediate component voltage, isolation resistance, and other possible characteristics associated with battery pack 102 can be indicators monitored by control module 106 to detect liquid intrusion inside battery pack 102. In other words, the monitored characteristics can indicate liquid intrusion inside battery pack 102. In various embodiments, the monitored characteristics may include the current value of isolation resistance, the behavior of intermediate component voltage over time, the behavior of isolation resistance over time, loss of communication with battery pack 102 (or more generally, the RESS of battery pack 102), the status of battery contactors checking for positive / negative stuck contactor faults, the status of disconnect switches, input from a humidity sensor, the status of detachable plugs (e.g., seals, etc.) in battery pack 102, brief indications of thermal management (e.g., increased temperature, increased heat dissipation, etc.), etc.

[0112] Then, control module 106 can set one or more flags based on the monitored characteristic. In such an example, control module 106 can set a flag for each monitored characteristic depending on whether the monitored characteristic meets a threshold. Thus, in some examples, if the monitored characteristic is within the defined threshold, control module 106 may not set a flag; if only one monitored characteristic meets its corresponding defined threshold, a flag is set; or if multiple monitored characteristics meet their corresponding defined thresholds, multiple flags are set.

[0113] For example, control module 106 may set a flag based on the current value of the isolation resistor. In such an example, control module 106 may implement a diagnostic algorithm to detect liquid in battery pack 102 by characterizing the system response. This diagnostic algorithm may use, for example, existing active isolation hardware to calculate the system's time constant (e.g., how quickly the circuit can change its voltage) by analyzing intermediate component voltages (e.g., negative intermediate component voltages). In such an example, the time constant is a parameter characterizing the system response and provides a correlation with the isolation resistor. For example, a larger time constant indicates a slower response time due to a higher isolation resistor, and a smaller time constant indicates a faster response time due to a lower isolation resistor. In such an example, control module 106 sets a flag if the calculated time constant falls outside a defined threshold. In other words, control module 106 sets a flag if the current value of the isolation resistor (or the calculated time constant) is below a defined threshold (e.g., indicating isolation loss). In such an example, the defined threshold may be 1.8 megohms (MΩ), 2 MΩ, 2.2 MΩ, or another suitable value.

[0114] Additionally, control module 106 can set one or more other flags based on the behavior of the isolation resistance over time. In such an example, control module 106 can implement another diagnostic algorithm to detect liquid in battery pack 102 by monitoring the unstable behavior of the system time constant across multiple timescales. In this example, the diagnostic algorithm takes the time constant as input and monitors both short-term (e.g., approximately several minutes) and long-term (e.g., approximately several days) unstable behavior. Then, based on the timescale at which the diagnostic algorithm detects the instability, control module 106 can set one or more different flags based on the severity of the fault. In other words, due to the correlation between the time constant and the isolation resistance, control module 106 can set one or more other flags based on the unstable behavior of the isolation resistance across multiple timescales. In such an example, control module 106 can set one or more flags based on unstable changes in the isolation resistance (e.g., sudden changes, large changes, etc.) and the expected behavior of the isolation resistance (or a defined threshold).

[0115] Furthermore, control module 106 can set another flag based on the time-varying behavior of intermediate component voltages (e.g., negative intermediate component voltages) received from voltage sensors(s) ... Figure 2 The unstable behavior of the isolation circuit in vehicle 200 is used to detect fluid in battery pack 102. Typically, the negative intermediate component voltage toggles in a predictable, monotonic manner. However, a diagnostic algorithm detects a fault when the negative intermediate component voltage deviates too far from its expected behavior. In such an example, control module 106 can set one or more flags based on the behavior of the intermediate component voltage and its expected behavior (or a defined threshold). For example, flags can be set based on changes in the intermediate component voltage over time from its expected behavior, such as the amplitude of the intermediate component voltage changing in an unexpected direction (e.g., the negative intermediate component voltage toggling in an unexpected direction).

[0116] In other examples, control module 106 may implement one or more other diagnostic algorithms to detect liquid in battery pack 102 by monitoring other characteristics or indicators in system 100, and then set a flag based on the monitoring. In such an example, control module 106 can... Figure 1 Multiple sensors 108 receive characteristics / indicators as input. For example, the control module 106 may receive sensor inputs related to communication loss, battery contactor status, disconnector status, input from humidity sensor, detachable plug status, thermal management indicators (e.g., increased temperature, increased heat dissipation, etc.), and then set one or more flags based on such inputs.

[0117] In various embodiments, the control module 106 then identifies the severity level of liquid intrusion within the battery pack 102. In such an example, the identified severity level can be one of several possible severity levels. For example, the severity level can include a high severity level corresponding to a severe state of liquid intrusion and a low severity level corresponding to a liquid intrusion state that is less severe compared to the high severity level. In other examples, the severity level can include an intermediate level between a high severity level and a low severity level.

[0118] exist Figure 1 In the example, control module 106 can identify the severity level based on which one or more characteristics cause one or more flags to be set. Using this method, control module 106 identifies the severity level based on which one or more flags are set and values ​​not associated with such flags. For example, if only one flag is set, control module 106 can identify the severity level based on the characteristic that causes that flag. In other examples, if multiple flags are set, control module 106 can implement a fusion algorithm to identify the severity level based on the characteristics that cause multiple flags. In such examples, some characteristics can automatically cause the severity level to rise to a high severity level, regardless of whether other flags are set or multiple other flags are set. In such examples, setting a single flag based on a specific characteristic or multiple flags having that single flag can cause control module 106 to identify the severity level as high. In other examples, if a characteristic indicates a less severe liquid intrusion, multiple flags set based on multiple characteristics can cause control module 106 to identify the severity level as low.

[0119] For example, control module 106 may identify a severity level as high when the flag is set based on the current value (or calculated time constant) of the isolation resistance being below a defined threshold. In such an example, control module 106 may make this severity level identification if the flag is simply set or one of multiple set flags. In other words, the isolation resistance falling below the defined threshold is a critical characteristic, and the flag set due to this characteristic causes control module 106 to identify the severity level as high, regardless of whether other flags are set (or not).

[0120] In other examples, when the flags are set based on the unstable behavior of the intermediate component voltage over time or the behavior of the isolation resistance over time, the control module 106 can identify the severity level as low or even lower. For example, if two flags are set based on the change of the intermediate component voltage over time and a defined threshold, and the change of the isolation resistance over time and another defined threshold, the control module 106 can identify the severity level as low severity.

[0121] Then, control module 106 can select at least one remedial measure to remedy liquid intrusion inside battery pack 102 in response to the identified severity level. In such an example, the selected remedial measure(s) can be one or more of a plurality of available remedial measures. For example, the remedial measures may include a set of emergency remedial measures corresponding to different measures corresponding to high or higher severity levels, and a set of less urgent or non-urgent remedial measures corresponding to different measures corresponding to low or lower severity levels. In such an example, emergency remedial measures may be critical because the severity of liquid intrusion may result in isolation loss relative to battery pack 102, and subsequently an increased risk of electric shock and / or fire. Thus, control module 106 can select one or more emergency remedial measures in response to the severity level being identified as high severity level. In contrast, less urgent or non-urgent remedial measures may be less critical because the severity of liquid intrusion may potentially result in future (e.g., one week, two weeks, one month, etc.) isolation loss, and subsequently an increased risk of electric shock and / or fire if no measures are taken. Thus, control module 106 can select one or more non-urgent remedial measures in response to the severity level being identified as low severity level.

[0122] In various embodiments, emergency and non-emergency remedial measures may include any suitable measures for remedying liquid intrusion. For example, and as further explained below, emergency remedial measures may include changing the charging control settings of battery pack 102, changing the cooler control settings of vehicle 200, changing the power limit settings of vehicle 200, changing the coolant pump control settings, setting diagnostic fault codes (DTCs), providing emergency driver notification, etc. Similarly, non-emergency remedial measures may include changing the state-of-charge limits of battery pack 102, changing the power limit settings of vehicle 200, setting DTCs, providing driver notification, etc.

[0123] exist Figure 1 In the example, control module 106 may be based on the identified severity level in conjunction with battery pack 102 and / or vehicle (e.g., Figure 2 Other parameters related to other battery packs in the vehicle (200), vehicle-related parameters, etc., are used to select appropriate remedial measures(s). For example, control module 106 may include one or more lookup tables stored in memory circuitry 118. In such an example, memory circuitry 118 may be internal to control module 106, such as... Figure 1As shown, or external to the control module 106, but accessible by the control module 106. Using this method, different (multiple) available remedies can be provided for the configuration parameters of the battery pack 102, vehicle, etc. For example, depending on the vehicle's brand, model, trim package, etc., some (multiple) remedies may be unavailable. As an example, a particular vehicle may not include a cooler, and therefore the remedies for that vehicle may not include changing the cooler control settings of vehicle 200.

[0124] In various embodiments, the selected remedies(s) can be implemented automatically without user input. For example, in response to the selected remedies(s), control module 106 can generate one or more control signals to implement the remedies(s). Control module 106 can then transmit the control signals to other suitable modules to implement the remedies(s).

[0125] For example, if the chosen remedy is to provide a driver notification (e.g., emergency driver notification, regular driver notification, etc.), control module 106 can generate a control signal and transmit it to display module 110, causing display module 110 to display the driver notification. In such an example, the driver notification could be a Driver Information Center (DIC) message for reducing power, repairing high-voltage (HV) systems, etc.

[0126] Furthermore, for example, if the selected remedy involves changing the vehicle's power limit setting, the control module 106 can generate a control signal and transmit it to the vehicle control module 112. For example, after receiving the control signal, the vehicle control module 112 can reduce the vehicle's propulsion power, stop the vehicle, or automatically pull over to the side of the road, depending on whether the remedy is urgent or non-urgent.

[0127] Furthermore, if the chosen remedy includes, for example, changing the charging control settings of battery pack 102, control module 106 can generate a control signal and transmit it to battery charging control module 114. For example, after receiving the control signal, battery charging control module 114 can reduce the charging power supplied to battery pack 102, stop or prevent DC fast charging (DCFC) of battery pack 102, reduce the state of charge (SOC) limit of battery pack 102, etc., depending on whether the remedy is urgent or non-urgent.

[0128] Furthermore, for example, if the chosen remedy involves changing the cooler control settings, the control module 106 can generate a control signal and transmit it to the cooler control module 116. For example, upon receiving the control signal, the cooler control module 116 can stop or prevent the cooler from requesting activation, stop the flow of coolant to the battery pack 102, etc.

[0129] Figure 5 Another example system 500 for detecting and remediating liquid intrusion inside a battery pack is depicted. In terms of its function, system 500 is generally similar to... Figure 1 The system 100, but includes specific control components for implementing its functions. For example, and such as Figure 5 As shown, system 500 includes multiple sensors, multiple monitors, a sensor fusion module 502, and a risk mitigation module 504. In this example, the monitors, sensor fusion module 502, and risk mitigation module 504 may be part of a control module, for example... Figure 1 Control module 106.

[0130] exist Figure 5 In this example, the sensors include a communication loss sensor 506, a contactor status sensor 508, a disconnector switch sensor 510, a battery pack voltage sensor 512, an intermediate component voltage sensor 514, and a thermal management sensor 516. In such an example, the battery pack voltage sensor 512 and the intermediate component voltage sensor 514 can correspond to... Figure 1 Multiple voltage sensors 104, and other sensors 506, 508, 510, 516 can correspond to Figure 1 The (multiple) sensors 108 in the middle. Figure 5 The monitors include a communication loss monitor 518, an intermediate component unstable voltage monitor 520, a reduced isolation monitor 522, an isolation resistance unstable monitor 524, a contactor monitor 526, and a humidity / decomposable plug monitor 528.

[0131] exist Figure 5 As described herein, monitors can generate and set flags based on inputs from sensors. For example, the reduced isolation monitor 522 can set a flag based on the current value of the isolation resistance (e.g., calculated based on the battery pack's output voltage and intermediate component voltage), as described above. Furthermore, as described above, the intermediate component unstable voltage monitor 520 and the isolation resistance unstable monitor 524 can set flags based on the behavior of the intermediate component voltage and the behavior of the isolation resistance, respectively. Additionally, the communication loss monitor 518, contactor monitor 526, and humidity / decomposable plug monitor 528 can set flags based on inputs from the communication loss sensor 506, contactor status sensor 508, disconnector switch sensor 510, thermal management sensor 516, etc.

[0132] As described above, the sensor fusion module 502 then receives the set flag(s) and identifies the severity level of liquid intrusion into the battery pack. As described above, after identifying the severity level, the risk mitigation module 504 selects one or more remedies from, for example, a set 530 of low-severity remedies and / or a set 532 of high-severity remedies.

[0133] Figure 6-7 The diagram illustrates the process of... Figure 1 and 5 The systems 100 and 500 may employ example control processes 600 and 700 for detecting and remediating liquid intrusion inside a battery pack (e.g., battery pack 102). While related to the control module 106... Figure 1 The exemplary control processes 600 and 700 are described using system 100, but either control process 600 or 700 may be adopted by another suitable system.

[0134] like Figure 6 As shown, the control process 600 receives a battery pack (e.g., Figure 1 The control module 106 begins with the intermediate component voltage and output voltage of the battery pack 102. For example, and as described above, the control module 106 can receive signals from the voltage sensor(s) 104 indicating the negative intermediate component voltage and output voltage of the battery pack 102. Control process 600 then proceeds to 604, where the control module 106 determines the isolation resistance of the battery pack based on the intermediate component voltage and output voltage, as described above. Control process 600 then proceeds to 606.

[0135] At 606, control module 106 monitors characteristics associated with the battery pack that indicate liquid intrusion within the battery pack. For example, and as described above, control module 106 may monitor the current value of the isolation resistor, the behavior of intermediate component voltages over time, the behavior of the isolation resistor over time, etc. Then, at 608, control module 106 determines whether any of the monitored characteristics is less than or greater than a corresponding defined threshold. If not, control process 600 returns to 602 or another suitable step, such as 606. If yes at 608, control process 600 proceeds to 610.

[0136] At 610, control module 106 sets one or more flags based on the monitored characteristic. For example, and as explained above, control module 106 may set a flag for each monitored characteristic depending on whether the monitored characteristic meets a threshold. Thus, control module 106 may set one or more flags, if applicable. Control process 600 then proceeds to 612.

[0137] At 612, control module 106 identifies the severity level of liquid intrusion into the battery pack. For example, and as described above, control module 106 may identify the severity level based on which one or more characteristics cause one or more flags to be set. In such an example, the identified severity level may be a high severity level corresponding to a severe state of liquid intrusion, a low severity level corresponding to a liquid intrusion state that is less severe than a high severity level, and / or an intermediate severity level between a high severity level and a low severity level.

[0138] Control process 600 then proceeds to 614, where control module 106 takes different actions based on the identified severity level. For example, if the severity level is identified as high severity (yes at 614), control process 600 proceeds to 618, where control module 106 selects one or more emergency remedies, as described above. However, if the severity level is not identified as high severity (no at 614), control process 600 proceeds to 616, where control module 106 selects one or more non-emergency remedies, as described above. Control process 600 then proceeds to 620, where control module 106 generates one or more control signals to implement the selected emergency or non-emergency remedies, as described above. Control process 600 then proceeds as follows: Figure 6 It can end as shown, or it can return to another appropriate step, such as 602, 606, etc.

[0139] exist Figure 7 In the middle, the control process 700 is similar to Figure 6 The control process is 600, but it includes additional steps. For example, and such as Figure 7 As shown, control process 700 in Figure 6 Starting at point 602, then proceeding to 604, 606, 608, and 610, as described above relative to... Figure 6 Explanation: Control process 700 then proceeds to 712.

[0140] At 712, control module 106 determines whether any of the flags set at 610 involves a reduction in the isolation resistance, for example, the current value of the isolation resistance falling below the threshold defined above. If not, control process 700 proceeds to 714, where control module 106 identifies the severity level of liquid intrusion into the battery pack as low severity. Control process 700 then proceeds to the above-described... Figure 6 616, 620. However, if yes at 712, then control process 700 proceeds to 716, where control module 106 identifies the severity level of liquid intrusion inside the battery pack as high severity. Control process 700 then proceeds to the above-described... Figure 6618, 620. Control process 700 then as follows Figure 7 It can end as shown, or it can return to another appropriate step, such as 602, 606, etc.

[0141] The foregoing description is merely illustrative in nature and is in no way intended to limit this disclosure, its application, or use. The broad teachings of this disclosure can be implemented in many forms. Therefore, while this disclosure includes specific examples, its true scope should not be so limited, as other modifications will become apparent upon examination of the drawings, specification, and the following claims. It should be understood that one or more steps within the method may be performed in a different order (or simultaneously) without altering the principles of this disclosure. Furthermore, while each of the embodiments is described above as having certain features, any one or more of those features described with respect to any embodiment of this disclosure may be implemented in any other embodiment and / or combined with features of any other embodiment, even if that combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and substitutions of one or more embodiments for each other remain within the scope of this disclosure.

[0142] Various terms are used to describe spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.), including “connection,” “joint,” “coupled,” “adjacent,” “right next to,” “on top of,” “above,” “below,” and “set.” Unless explicitly described as “direct,” when describing the relationship between first and second elements in the above disclosure, that relationship can be a direct relationship where no other intermediate element exists between the first and second elements, but it can also be an indirect relationship where one or more intermediate elements (spatial or functional) exist between the first and second elements. As used herein, the phrase “at least one of A, B, and C” should be interpreted as meaning a logic using the non-exclusive logic “OR” (A or B or C) and should not be interpreted as meaning “at least one of A, at least one of B, and at least one of C.”

[0143] In a diagram, the direction of the arrows typically indicates the flow of information (e.g., data or instructions) that is of interest to the diagram. For example, when elements A and B exchange various types of information, but the information transmitted from element A to element B is relevant to the diagram, the arrow can point from element A to element B. This unidirectional arrow does not mean that no other information is transmitted from element B to element A. Furthermore, for information sent from element A to element B, element B can send a request for or confirmation of receipt of that information to element A.

[0144] In this application, including the following definitions, the term "module" or "controller" may be replaced by the term "circuit". The term "module" may refer to or include some of the following: application-specific integrated circuit (ASIC); digital, analog, or mixed-signal analog / digital discrete circuit; digital, analog, or mixed-signal analog / digital integrated circuit; combinational logic circuit; field-programmable gate array (FPGA); processor circuitry (shared, dedicated, or grouped) that executes code; memory circuitry (shared, dedicated, or grouped) that stores code executed by the processor circuitry; other suitable hardware components that provide the described functionality; or some or all of the above, such as in a system-on-a-chip.

[0145] A module may include one or more interface circuits. In some examples, the interface circuits may include wired or wireless interfaces that connect to a local area network (LAN), the Internet, a wide area network (WAN), or a combination thereof. The functionality of any given module of this disclosure may be distributed among multiple modules connected via the interface circuits. For example, multiple modules may allow for load balancing. In another example, a server (also referred to as a remote or cloud) module may perform some functions on behalf of a client module.

[0146] The term "code," as used above, can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, data structures, and / or objects. The term "shared processor circuitry" covers a single processor circuitry that executes some or all of the code from multiple modules. The term "group processor circuitry" covers processor circuitry that, in conjunction with additional processor circuitry, executes some or all of the code from one or more modules. References to multiple processor circuitry cover multiple processor circuitry on a discrete die, multiple processor circuitry on a single die, multiple cores of a single processor circuitry, multiple threads of a single processor circuitry, or a combination of the above. The term "shared memory circuitry" covers a single memory circuitry that stores some or all of the code from multiple modules. The term "group memory circuitry" covers memory circuitry that, in conjunction with additional memory, stores some or all of the code from one or more modules.

[0147] The term "memory circuit" is a subset of the term "computer-readable medium." As used herein, the term "computer-readable medium" does not cover transient electrical or electromagnetic signals propagating through a medium (e.g., on a carrier wave); therefore, the term "computer-readable medium" can be considered tangible and non-transitory. Non-limiting examples of non-transitory tangible computer-readable media are non-volatile memory circuits (e.g., flash memory circuits, erasable programmable read-only memory circuits, or mask read-only memory circuits), volatile memory circuits (e.g., static random access memory circuits or dynamic random access memory circuits), magnetic storage media (e.g., analog or digital magnetic tape or hard disk drives), and optical storage media (e.g., CDs, DVDs, or Blu-ray discs).

[0148] The apparatus and methods described in this application can be implemented, in part or in whole, by a dedicated computer created by configuring a general-purpose computer to execute one or more specific functions contained in a computer program. The functional blocks, flowchart components, and other elements described above serve as software specifications that can be translated into computer programs by the routine work of skilled technicians or programmers.

[0149] A computer program includes processor-executable instructions stored on at least one non-transitory tangible computer-readable medium. A computer program may also include or depend on stored data. A computer program may encompass a basic input / output system (BIOS) for interacting with the hardware of a special-purpose computer, device drivers for interacting with specific devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0150] Computer programs may include: (i) descriptive text to be parsed, such as HTML (Hypertext Markup Language), XML (Extensible Markup Language), or JSON (JavaScript Object Notation); (ii) assembly code; (iii) object code generated from source code by a compiler; (iv) source code executed by an interpreter; (v) source code compiled and executed by a real-time compiler, etc. As an example only, source code may come from languages ​​including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, etc. Fortran, Perl, Pascal, Curl, OCaml, HTML5 (Hypertext Markup Language, Fifth Revision), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Visual Lua, MATLAB, SIMULINK and It is written using the syntax of the language.

Claims

1. A system for detecting and remediating liquid intrusion inside a vehicle's battery pack, the system comprising: A battery pack that includes multiple battery cells; The sensor is configured to sense the voltage of the intermediate components of the battery pack; and A control module that communicates with the one or more sensors, the control module being configured to: The isolation resistance of the battery pack is determined based on the voltage of the intermediate components. Monitor characteristics associated with the battery pack and indicate liquid intrusion inside the battery pack, including the current value of the isolation resistance, the behavior of intermediate component voltage over time, and the behavior of the isolation resistance over time; Set one or more flags based on the monitored characteristics; Based on which one or more of the aforementioned characteristics cause the one or more flags to be set, the severity level among multiple severity levels of liquid intrusion into the battery pack is identified; and In response to the identified severity level, at least one of a plurality of remedial measures is selected to remedy liquid intrusion inside the battery pack.

2. The system according to claim 1, wherein, The control module is configured to generate control signals for implementing the at least one selected remedial measure.

3. The system according to claim 1, wherein, The plurality of severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe compared to the first severity level.

4. The system of claim 3, wherein the control module is configured to identify a first severity level of liquid intrusion inside the battery pack when the current value of the isolation resistor is less than a defined threshold.

5. The system according to claim 4, wherein: Multiple remedial measures include a set of emergency remedial measures and a set of non-emergency remedial measures; and The control module is configured to select at least one of the emergency remedies in response to identifying the first severity level.

6. The system of claim 5, wherein the set of emergency remedial measures includes changing the charging control settings of the battery pack, changing the cooler control settings of the vehicle, changing the power limit settings of the vehicle, changing the cooling pump control settings, setting diagnostic fault codes (DTCs), and providing emergency driver notification.

7. The system of claim 3, wherein the control module is configured to identify a second severity level of liquid intrusion inside the battery pack based on a change in the voltage of the intermediate component over time and a first threshold or a change in the isolation resistance over time and a second threshold.

8. The system according to claim 7, wherein: Multiple remedial measures include a set of emergency remedial measures and a set of non-emergency remedial measures; The control module is configured to select at least one non-emergency remedy in response to identifying a second severity level; and This group of non-emergency remedies includes changing the battery pack's state of charge limits, changing the vehicle's power limit settings, setting diagnostic fault codes (DTCs), and providing driver notification.

9. The system according to claim 1, wherein: The plurality of severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a state of liquid intrusion that is less severe compared to the first severity level; The one or more flags include at least a first flag set based on the current value of the isolation resistance and a second flag set based on the behavior of the intermediate component voltage over time or the behavior of the isolation resistance over time; and The severity level identified is Level 1.

10. The system according to claim 1, wherein: The plurality of severity levels include a first severity level corresponding to a severe state of liquid intrusion and a second severity level corresponding to a liquid intrusion state that is less severe compared to the first severity level; The one or more flags include at least a first flag set based on the behavior of intermediate component voltage over time and a second flag set based on the behavior of isolation resistance over time; and The severity level identified is level two.

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