Determination of battery temperature and temperature measurement location using models

Abstract

A method for estimation of temperature distribution of a battery (10) is described. The method is implemented by the battery management system (BMS). The battery has a shell that includes a housing and a cover. The housing and the cover of the shell define an interior space. The method includes determining at least one of a finite element analysis (FEA) and a thermal model and computational fluid dynamic (CFD) thermal model based on at least one temperature value associated with a temperature of the interior space, determining a reduced order model (ROM) based on at least one of the FEA thermal model and the CFD thermal model, and determining a location inside the battery for placement of a battery sensor configurable to measure temperature. The location is determined based upon at least one of the FEA thermal model, the CFD thermal model, and the ROM.

Description

[0001] DETERMINATION OF BATTERY TEMPERATURE AND TEMPERATURE MEASUREMENT LOCATION USING MODELS

[0002] TECHNICAL FIELD

[0003] This disclosure relates to energy storage units such as batteries, and in particular to battery management systems. More particularly, this disclosure relates to a system and a method for determining a temperature or other parameter of a battery. Also described are related systems and methods.

[0004] BACKGROUND

[0005] Batteries are an essential part of many devices, including motor vehicles. Motor vehicles are typically equipped with one or more batteries, e.g., a lead acid battery, used to both start the vehicle’s motor as well as to power the other systems of the vehicle, e.g., charging system, operation while running, lighting, accessories, etc. Reliability of batteries generally depends on the battery health, i.e., condition of the battery. However, many typical batteries do not provide information about battery health, e.g., usable to predict battery health degradation, potential failures, etc. In other words, many typical batteries degrade over time and fail suddenly (e.g., fail to provide requisite power) without warning to the user / owner of the battery. Accordingly, real-time battery reliability / condition is unknown to the user / owner, and the user / owner cannot take actions to prevent potential battery failures.

[0006] Vehicles, including but not limited to cars, trucks, boats, motorcycles, and recreational vehicles rely on batteries to provide power to the vehicle. The battery may also be used in a vehicle to provide power to auxiliary features including alarm systems, keyless entry, computer systems in the vehicle, lights, as well as other vehicle components. Since many typical batteries do not provide information about battery health, the battery can sometimes fail suddenly and create safety issues as well as other hazards when the battery is being used. Batteries which are used with a vehicle may be exposed to adverse environmental elements including temperature, humidity, rain, and wind and these adverse environmental elements may impact the condition of the battery. For example, over time, these environmental elements can cause the battery to deteriorate and / or cause damage to the battery which may result in the battery unexpectedly failing. While the failure may seemingly be without warning and occur instantly, it is possible that there was a gradual, but unobserved, deterioration in one or more battery components. Even under typical operating conditions, batteries can also be impacted by unexpected and / or unforeseen conditions that are in and around the battery as well. As a result, batteries used in vehicles can unexpectedly fail and / or be seen by the user as unreliable with the exposure of the battery to adverse environmental elements and expected and / or unforeseen conditions.

[0007] SUMMARY

[0008] Some embodiments advantageously provide a method, apparatus, and system for determining and / or communicating, such as via a battery management system (BMS), one or more parameters associated with a battery. The battery parameters may be associated with one or more battery states and / or used to determine (and / or diagnose and / or forecast) one or more battery states and / or other parameters. Determining one or more battery states may include determining optimized states, state of health (SoH), abuse / faults associated with the battery, e.g., to keep the battery in one or more optimized states, communicate parameters and / or other determinations such as when a preventive battery replacement is suggested (and / or necessary). Such determinations are beneficial at least because the user (and / or owner and / or manufacturer) of the battery may be informed of battery parameters / states and avoid unexpected battery failures.

[0009] In some embodiments, a location of a temperature sensor associated with a battery is determined using one or more models. The models may be based on temperature measurement data which may be collected in a testing environment.

[0010] According to one aspect, a method for estimation of temperature distribution of a battery is described. The battery includes a battery management system (BMS). The method is implemented by the BMS. The battery has a shell including a housing and a cover. The housing and the cover of the shell define an interior space. The method includes determining at least one of a finite element analysis (FEA) thermal model and a computational fluid dynamic (CFD) thermal model based on at least one temperature value associated with a temperature of the interior space. The method also includes determining a reduced order model (ROM) based on at least one of the FEA thermal model and the CFD thermal model, and determining a location inside the battery for placement of a battery sensor configurable to measure temperature. The location is determined based upon at least one of the FEA thermal model, the CFD thermal model, and the ROM.

[0011] In some embodiments, the battery further includes a plurality of cells housed within the interior space, and the at least one temperature value is associated with the temperature of at least one cell of the plurality of cells. In some other embodiments, the ROM is further determined based at least on one condition associated with the battery, where the at least one condition associated with the battery is at least one of the temperature, a pressure, and a humidity.

[0012] In some embodiments, the battery is an absorbent glass mat (AGM) battery having at least one glass mat separator in the interior space, and the at least one temperature value is associated with the temperature of the glass mat separator.

[0013] In some other embodiments, the location inside the battery for placement of the battery sensor is further based on the temperature of the glass mat separator.

[0014] In some other embodiments, the method further includes performing, by the BMS, at least one action based on at least one of the location, the FEA thermal model, the CFD thermal model, and the ROM.

[0015] In some embodiments, the at least one action includes at least one of: (A) determining at least one of a report, an indication, a configuration, and a message comprising information associated with the location, the sensor, the FEA thermal model, the CFD thermal model, and the ROM; (B) transmitting signaling including at last one of the report, the indication, the configuration, and the message; (C) activating the battery sensor; and (D) deactivating the battery sensor. Other actions may include the BMS enabling or disabling a BMS operating mode (e.g., sleep mode to perform BMS functions at a reduced rate, active mode to perform BMS functions at a greater rate than the reduced rate, etc.), enabling or disabling a battery operating mode (e.g., enabling or disabling cells, the battery, etc.), predict that the battery will perform or fail to perform according to a set of battery performance requirements, transmit an indication of a battery state based on the prediction, etc.

[0016] In some other embodiments, the BMS is configured to communicate with at least one of a server and a vehicle, the transmitted signaling triggering at least one of the server and the vehicle to perform at least one other action. For example, server may determine any model described in the present disclosure and / or battery sensor location, determine a configuration using the model, transmit the configuration to another BMS and cause the other BMS to be configured with the configuration and perform actions according to the configuration. The vehicle may perform another action such as displaying an alert for the driver regarding a temperature at the location of the battery sensor, cause the vehicle to operate according to a temperature value measured by the battery sensor, activate another battery for use by the vehicle, etc.

[0017] According to another aspect, a method for determining a distribution of temperature values inside a battery is described. The battery has a shell defining an interior space with the shell having an outer surface exposed to an exterior environment. The battery includes a plurality of cells housed within the interior space, and the shell comprises a plurality of apertures. The method includes inserting a plurality of probes into the interior space of the battery through a plurality of apertures, where each probe from the plurality of probes has at least one sensor that is configured to measure a temperature of the interior space. The method also includes determining at least one temperature value associated with at least one sensor on each probe from the plurality of probes. Further, the method includes determining a finite element analysis (FEA) thermal model based on the at least one temperature value and an exterior environment temperature and determining a reduced order model (ROM) based on at least one of the FEA thermal model and the at least one temperature value. In addition, the method includes determining a location inside the battery for placement of a battery sensor that is configurable to measure temperature based upon at least one of the FEA thermal model and the ROM.

[0018] Further, in some other embodiments, the ROM is further determined based at least on one condition associated with the battery, where the at least one condition associated with the battery is at least one of a temperature, a pressure, and a humidity.

[0019] In some embodiments, the plurality of probes includes nine separate probes.

[0020] In some other embodiments, each probe is inserted into a different cell of the battery.

[0021] In some embodiments, the method further comprises performing, by each sensor, one or more measurements of the temperature value inside the battery.

[0022] In some other embodiments, the method further includes transmitting an indication indicating the measurement of the at least one temperature value associated with at least one sensor on each probe from the plurality of probes.

[0023] In some embodiments, the measuring at least one temperature value associated with the at least one sensor on each probe from the plurality of probes further includes measuring a plurality of temperature values associated with the at least one sensor on each probe from the plurality of probes over a twenty-four hour period.

[0024] In some other embodiments, the battery is an absorbent glass mat (AGM) battery having at least one glass mat separator in the interior space, and the method further includes inserting one probe from the plurality of probes into the interior space of the battery through one aperture from the plurality of apertures. The corresponding sensor is placed proximate to the at least one glass mat separator and is arranged to measure the temperature of the glass mat separator. In some embodiments, the location inside the battery for placement of the battery sensor is further based on the temperature of the glass mat separator.

[0025] According to one aspect, a battery is described. The battery includes a battery management system (BMS) a shell defining an interior space, a plurality of cells housed within the interior space, and at least one sensor in communication with the BMS. The sensor has a location within the battery that is based upon at least one of a finite element analysis (FEA) thermal model and a reduced order model (ROM). The FEA thermal model is based on the at least one temperature value and an exterior environment temperature. The ROM is based on at least one of the FEA thermal model and the at least one temperature value. The at least one temperature value is associated with a temperature of the interior space associated with at least one cell from the plurality of cells.

[0026] In some embodiments, the at least one sensor includes a first sensor and a second sensor. The first sensor is associated with a first sensor location within the interior space, and the second sensor is associated with a second sensor location within the interior space.

[0027] In some other embodiments the BMS is configured to obtain a first configuration that includes the FEA thermal model, the ROM, and location information corresponding to the first sensor. The BMS is also configured to obtain a second configuration including the FEA thermal model, the ROM, and location information corresponding to the second sensor, and activate at least one of the first sensor and the second sensor based on the first configuration and the second configuration.

[0028] According to one aspect, a battery is described. The battery includes a battery management system (BMS), a shell defining an interior space, and a plurality of cells housed within the interior space. The battery also has a first sensor in communication with the BMS. The first sensor has a first location within the battery that is based upon at least one of a first finite element analysis (FEA) thermal model and a first reduced order model (ROM). The first FEA thermal model is based on the at least a first temperature value and an exterior environment temperature. The first ROM is based on at least one of the first FEA thermal model, and the at least one temperature value is associated with a first temperature of the interior space. The battery also has a second sensor in communication with the BMS. The second sensor has a second location within the battery that is based upon at least one of a second FEA thermal model and a second ROM. The second FEA thermal model is based on the at least a second temperature value and an exterior environment temperature. The second ROM is based on the second FEA thermal model, and the at least one temperature value is associated with a second temperature of the interior space. The BMS is configured to activate at least one of the first sensor and a second sensor based on at least one of the first FEA thermal model, the first ROM, the second FEA thermal model, and the second ROM.

[0029] BRIEF DESCRIPTION OF THE DRAWINGS

[0030] A more complete understanding of embodiments described herein, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

[0031] FIG. 1 shows a block diagram of an example battery constructed in accordance with the principles of present disclosure;

[0032] FIG. 2 shows an example system in accordance with the principles of present disclosure;

[0033] FIG. 3 shows an example battery management system (BMS) according to the principles of the present disclosure;

[0034] FIG. 4 shows an example battery including one or more apertures and one or more probes according to the principles of the present disclosure;

[0035] FIG. 5 shows an example battery including one or more probes and sensors penetrating into various areas inside the battery according to the principles of the present disclosure;

[0036] FIG. 6 shows an example system in accordance with the principles of present disclosure;

[0037] FIG. 7 shows an example method for estimation of temperature distribution of a battery according to the principles of the present disclosure; and

[0038] FIG. 8 shows another example method in accordance with the principles of present disclosure.

[0039] DETAIEED DESCRIPTION

[0040] Before describing in detail exemplary embodiments, it is noted that the embodiments reside primarily in combinations of apparatus components and processing steps related to determination of battery temperature and temperature measurement location using models such as might be used in connection with, for example, a lead acid or Ei-Ion battery. Accordingly, the system and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0041] As used herein, relational terms, such as “first” and “second,” “top” and “bottom,” and the like, may be used solely to distinguish one entity or element from another entity or element without necessarily requiring or implying any physical or logical relationship or order between such entities or elements. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the concepts described herein. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and / or “including” when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0042] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0043] In embodiments described herein, the joining term, “in communication with” and the like, may be used to indicate electrical or data communication, which may be accomplished by physical contact, induction, electromagnetic radiation, radio signaling, infrared signaling or optical signaling, for example. In some embodiments, “in communication with” refers to transmission / reception of signals which may include data, information, models, configurations, etc. usable by any other components to perform one or more actions. One having ordinary skill in the art will appreciate that multiple components may interoperate and modifications and variations are possible of achieving the electrical and data communication.

[0044] In some embodiments, the term “parameter” may refer to a numerical or other value, e.g., an input, an output, etc. The parameter may be measurable and / or determinable and / or communicated and / or associated with a battery and / or battery component and / or other devices / systems. Parameter may also refer to a quantity selectable for a predetermined situation and / or be based on one or more parameters / states / variable. Further, a parameter may be a state. The term state may refer to a battery state and / or state associated with other devices / systems. In one nonlimiting example, a parameter may be temperature. In some embodiments, the term “model” is used and may refer generally to a logical representation of a system, entity, phenomenon and / or process. For example, a model may be a system of postulates, data, and / or inferences which are presented in a description e.g., mathematical type description. One non-limiting example of a model may be for a Finite Element Analysis (FEA) model which is generally a computational technique that predicts a system’s behavior by breaking it down into smaller and simpler parts referred to as “finite elements.” Each of the finite elements in the FEA model may be individually analyzed under specific conditions and circumstances and the combined responses of the finite elements are then used to predict the overall behavior of the system. Another non-limiting example of a model is the Computational Fluid Dynamics (CFD) model. Further, another example of a model is a Reduced Order Model (ROM). A ROM is generally a simplified version of the FEA model. The ROM captures the critical behavior of the complex FEA model and allows those using the ROM to quickly and / or efficiently study the system’s main effects with less computational resources than are required by the FEA model. Accordingly, while the FEA model provides a detailed and complex model of the system, the ROM simplifies the FEA model while preserving the key characteristics of the FEA model. This makes ROM a powerful tool (e.g., for engineers who need) to analyze and predict system behavior efficiently. It will be understood that the FEA model and the ROM are two examples of models that may be used but that other models may also be used as well.

[0045] Referring now to the drawing figures in which like reference numbers refer to like elements, there is shown in FIG. 1, a battery 10 constructed in accordance with the principles of the present disclosure. Battery 10 includes a housing 12 into which one or more cells 14 are positioned. The cells 14 may be electrically interconnected (not shown in the FIGS), such as via an electrically conductive bus bar system which electrically interconnects the cells 14 in an electrically serial, electrically parallel or combination of electrically serial and parallel manner, depending on the intended voltage and current requirements.

[0046] A battery monitoring system (BMS) 16 may also be included with the battery 10. In some embodiments, the BMS 16 may measure certain battery parameters, e.g., voltage, temperature, pressure, power, current, etc., perform determinations based on one or more models, and provide the data and / or models to an external system. BMS 16 may include a monitoring connector 18 that allows for an external connection to the vehicle’s data bus, or to some other communication device so that data may be transferred. The monitoring connector 18 can, in some embodiments, be integrated with the housing 12, such as in a cover 20 of the housing 12. If the monitoring connector 18 is integrated into the cover 20 of the housing 12, the exterior surface of the cover 20 may be smooth, e.g., if the monitoring connector 18 is entirely contained within the cover 20 and / or the housing 12. In another embodiment, the monitoring connector 18 may be arranged to protrude through housing 12, such as protruding through cover 20 so that the cover 20 is not a smooth surface. Battery 10 also includes terminals, such as a negative terminal 22a and a positive terminal 22b (collectively referred to as terminals 22) to provide the contact points for electrical connection of the battery 10 to the vehicle to provide power to the vehicle including the auxiliary power to the vehicle.

[0047] Terminals 22 are arranged to protrude through housing 12, such as protruding through cover 20. Terminals 22 may be electrically connected to the bus bars inside housing 12 and / or directly connected to the cells 14 (not shown in the FIGS).

[0048] Battery 10 may also include a shell 29 which may include the housing 12 and the cover 20. Shell 29 may define an interior space 31, i.e., interior volume, of the battery 10. For example, the interior space 31 may be defined by the cover 20 and the housing 12, and the interior space 31 contains the cells 14. It will be understood that the interior space 31 of the battery 10 may also contain other components of the battery 10 as well. Further, the battery 10 (and / or the outer surface 37 of the shell 29) may be surrounded by an exterior environment 33, and the exterior environment 33 may be the surroundings and ambient conditions of the battery 10.

[0049] In some embodiments, the housing 12 may include on or more apertures 25 and the apertures 25 may penetrate through the exterior of the housing 12 to the inside of the battery 10. In this nonlimiting example, the housing 12 may include apertures 25a, 25b, and 25c (collectively referred to apertures 25). The apertures 25 may allow access to the interior space 31 which may include one or more of the cells 14 within the battery 10 or other components of the battery 10 as well.

[0050] Further, battery 10 (and / or battery housing 12) may be arranged for measuring one or more parameters (e.g., temperature) associated with various portions / locations of battery 10 via one or more probes 26a, 26b, and 26c, (collectively referred to as probes 26) and / or BMS 16 (e.g., where BMS 16 may be electrically connected to the probes 26, and the probes 26 may be connected to or proximate certain locations within the battery 10 and / or exposed to the outside the battery 10). For example, battery temperature may be measured and / or predicted using probes 26, e.g., to determine battery performance, and the probes 26 may have access to various components within the battery 10 through the apertures 25. As a nonlimiting example, when the probes 26 ae inserted into the battery 10 through the housing 12, each aperture 25 may have a seal so that the internal components of the battery 10 are protected (and / or insulated) from the outside environment when probe 26 is inserted into each aperture 25 or when probe 26 is removed from aperture 25.

[0051] Each probe 26 may include at least one sensor 27 that is in electrical communication with another component of the battery 10 or any other component of system 30. As a nonlimiting example, the at least one sensor 27 may be in electrical communication with the BMS 16. Sensors 27a, 27b, 27c are shown and are collectively referred to as sensors 27. In this nonlimiting example, probe 26a includes sensor 27a, probe 26b includes sensor 27b, and probe 26c includes sensor 27c. However, a probe 26 may include one or more sensors 27 which may be associated with each probe 26 and in electrical communication with another component of the battery 10. Sensor 27 may be releasably secured to probe 26 or sensor 27 may be permanently secured to the probe 26. Sensor 27 may include a temperature sensor, a proximity sensor, a pressure sensor, a motion sensor, a humidity sensor, a gas sensor, or another type of sensor. In some embodiments, sensor 27 may include a thermocouple or thermoelectrical thermometer which may be configured to measure temperature and provide an electrical signal within a range, e.g., 25 - 30 millivolts, which may be mapped to a temperature range.

[0052] Using the probes 26 and at least one sensor 27 to measure the temperature of the battery 10 over a period of time, a temperature model may be generated based on various temperature values that are generated over time (e.g., across time). As a non-limiting example, the period of time may depend upon the type of testing and modeling being conducted and could vary. In one non-limiting example, the time period may be between a 24 hour time period and a 36 hour time period. However, it will be understood that this time period may be more or less based upon a variety of different factors including but not limited to the type of testing, the type of modeling being conducted, as well as the battery 10. Other and / or additional factors may be considered when determining the period of time as well.

[0053] The various temperature values may be used to create a temperature profile for one or more locations of the battery 10 and / or location of sensor 28. The temperature profile for various locations of the battery 10 may be the same, or the temperature profile at various locations of the battery 10 may be different from one another as well. As a non-limiting example, probe 26 may be inserted into housing 12 through aperture 25, and sensor 27 that is included with probe 26 may be placed proximate a component within the housing 12. The component within the housing 12 may include a battery cell 14, the BMS 16, the monitoring connector 18, the cover 20, the terminals 22, or any other location within the housing 12. Further, one or more temperature distributions may be determined based on the various temperature values. As a non-limiting example, the various temperature values may come from the sensors 27 that are placed through the housing 12 of the battery 10 in various different locations inside the battery 10 housing 12. Alternatively, the various temperature values may come from sensors 27 that are placed in similar locations inside the battery 10 housing 12. In some embodiments, at least one sensor 27 may be placed outside battery 10. In addition, a model (e.g., based on one or more parameters) may be generated, where the model can be used to predict the temperature distribution associated with the battery 10. The model may further be used to determine one or more locations usable to measure temperature that has a greater probability to affect / determine battery performance.

[0054] Various different types of information may be used with an FEA model to be able to predict the temperature inside the battery 10. The different types of information may be referred to as inputs to the FEA model. As a non-limiting example, the geometry of the battery 10 may be included, and the geometry of the battery 10 may include the shape and size of the battery 10 along with the components of the battery 10. Alternatively, the geometry may be based upon simplified dimensions for the battery 10 (e.g., simplified dimensions based on model). Various material properties may also be included in the FEA model. The material properties may be characteristics of the battery 10 material that may affect how the battery 10 heats up and / or cools down. Various components of the battery 10 can have different temperatures inside the battery 10 based on the material properties differences of each component. Also, the FEA model may also be based on boundary conditions. The boundary conditions may be conditions that are found outside the battery 10 and / or at the surface of the battery 10. As a non-limiting example, boundary conditions may include the temperature at the surface of the battery housing 12 which may include the outside temperature and / or any heat sources. The FEA model may also be based on initial conditions which may include the starting temperature of all components inside the battery 10 at a particular preset and / or predetermined time. The FEA model may also include or be based on mesh details as well which may take int account specific smaller portions and / or sections of the battery (e.g., a net over the battery, a plurality of portions / section of the battery, etc.) as part of the analysis. When using the mesh details, the size and shape of the smaller portions and / or sections of the battery 10 can impact the results from the FEA model such as when analysis performed for each portion / section that is used to determine the FEA model. The FEA model may also be based on time steps such that if the temperature in the battery 10 can change over time, a determination may be made as to how often the temperature is evaluated and / or checked. The time steps can be set at a variety of different increments, e.g. determining the temperature every 10 minutes, determining the temperature every 10 hours, and determining the temperature every 10 days. The FEA model may also be based on heat sources. For example, if there is element or component inside the battery housing 12 which may produce heat, a sensor 27 may be placed near and / or proximate a location inside the battery housing 12 that is producing heat to measure the heat being produced. These various inputs including the geometry, the material properties, the boundary conditions, the initial conditions, the mesh details, the time steps, and the heat sources may be used to help the FEA model understand the battery 10 and the various conditions with the battery 10, so that the FA model may be used to predict how the temperature will change inside the battery 10 at any specific location.

[0055] For example, the FEA model may be used with the battery 10 as the FEA model can be used to predict the temperature inside the battery 10 at specific locations by solving the heat transfer equation for specific given conditions. As a non-limiting example of how the FEA model may be used, the battery 10 may be divided (e.g., logically divided) into smaller parts, subparts, and / or elements which thereby creates a mesh or a plurality of parts, subparts, elements, or portions. Each part, subpart, and / or element may be connected to a nearby and / or neighboring parts, subparts, and / or elements at points called nodes. The known conditions, such as the external temperature of the battery 10, may be applied to the FEA model as “boundary conditions.” These boundary conditions may also include internal heat sources, material properties of the battery 10, or any other relevant factors that may be used in the FEA model. The heat transfer equation, which may be a differential equation, may be used to solve for the temperature, heat transfer or heat transfer coefficient of each part, subpart, and / or element in the mesh. The heat transfer equation may take into account the conduction, convection, radiation of heat, heat flux, difference in temperature between to areas / spaces of battery 10, etc. The temperature at each node may be calculated based on the solutions which are determined at the surrounding part, subpart, and / or element. The temperatures at all nodes together may be used to determine the temperature distribution inside the battery 10. Further, the temperature at any specific location inside the battery 10 (e.g., where sensor 28 may be located) may be then determined based upon this temperature distribution.

[0056] In some embodiments, the battery shape may be considered to be similar to a prism or polyhedron such as a box. FEA may be used to predict the temperature inside the box at a specific location by solving the heat transfer equation for given conditions. For example, the temperature may be determined performing or using one or more of the following: 1. Discretization: The box may be divided into smaller parts or elements, creating a mesh. Each element is connected to its neighbors at points called nodes.

[0057] 2. Boundary Conditions: The known conditions, such as the external temperature of the box, are applied as boundary conditions. These conditions may also include any internal heat sources, material properties of the box, or any other relevant factors.

[0058] 3. Solving the Equations: The heat transfer equation, a differential equation, is solved for each element in the mesh. This equation takes into account the conduction, convection, radiation of heat, and other elements.

[0059] 4. Aggregation: The temperature at each node is calculated based on the solutions of its surrounding elements. The temperatures at all nodes together give the temperature distribution inside the box.

[0060] 5. Prediction: The temperature at a specific location inside the box is then determined from the temperature distribution.

[0061] Further, battery 10 can be arranged to provide many power capacities and physical sizes, and to operate under various parameters and parameter ranges. It is also noted that in the implementations of battery 10 some can be scaled to provide various capacities. Power capacity scaling can be accomplished, for example, by using higher or lower power capacity cells 14 in the housing 12, and / or by using fewer or more cells 14 in the housing 12. In some embodiments, battery 10 may be incorporated as part of a vehicle such as an electric vehicle (EV) or another type of vehicle where battery power is needed. Other electrical parameters of the battery 10 can be adjusted / accommodated by using cells 14 that may cumulatively have the desired operational characteristics, e.g., voltage, charging capacity / rate, discharge rate, etc. Thermal properties can be managed based on cell 14 characteristics, the use of heat sinks and / or thermal energy discharge plates, etc., within or external to the housing 12.

[0062] Battery 10 may also include at least one sensor 28 which may be different from sensor 27. Sensor 28 may be in communication with BMS 16. Further, sensor 28 may include a temperature sensor, a proximity sensor, a pressure sensor, a motion sensor, a humidity sensor, a gas sensor or another type of sensor. Sensor 28 may be disposed at various locations within the battery 10 and / or external to the battery 10. While sensor 28 is shown as one sensor in FIG. 1, it will be understood that sensor 28 may include a plurality of sensors as well. For example, each sensor 28 of the plurality of sensors 28 may be associated with a different location within battery 10. Sensor 28 may be one sensor type such as a temperature sensor or the one sensor 28 may include a variety of different types of sensors in one sensor 28 including temperature sensor, a proximity sensor, a pressure sensor, a motion sensor, a humidity sensor, a gas sensor or another type of sensor. In another embodiment, sensor 28 may be a plurality of different sensors which may include different sensor types including a temperature sensor, a proximity sensor as well as other types of sensors. Further, battery 10 may comprise one or more post assemblies 35. The post assembly 35 may comprise a post and a strap coupled to the post. The post assembly 35 may be physically / electrically coupled to one or more cells 14 and may be electrically coupled to BMS 16, where BMS 16 may be configured to determine battery / cell parameters via post assembly 35. Although one post assembly 35 is shown, more than once cell 14 may be coupled to a post assembly 35, and one or more post assemblies 35 may be coupled to BMS 16.

[0063] FIG. 2 shows an example system 30 in accordance with the principles of present disclosure. System 30 may include one or more of each of the following: BMS 16, cloud network 32, server 34, and vehicle 36. In this nonlimiting example, BMS 16 may be configured to communicate with cloud network 32 and / or server 34 and / or vehicle 36. Cloud network 32 may be configured to provide communication functions and / or network functions to BMS 16 and / or server 34 and / or vehicle 36 such as access to one or more servers (e.g., server 34) and / or server functions. Server 34 may be any server, computer, client device, network node, network device, computing device, personal computer, laptop, etc. Server 34 may be configured to communicate with BMS 16 and / or cloud network 32 and / or vehicle 36. Server 34 may be standalone, integrated with BMS 16 and / or cloud network 32 and / or vehicle 36, etc. Similarly, BMS 16 may be standalone, part of a vehicle 36, part of battery 10, integrated with cloud network 32 and / or server 34, etc. Further, BMS 16 (and / or cloud network 32 and / or server 34 and / or vehicle 36) may be configured to perform any of the steps and / or tasks and / or methods and / or processes and / or features described herein, e.g., such as determining one or more parameters of a battery 10 and / or performing communication functions such as transmitting / receiving one or more messages associated with one or more parameters.

[0064] Now referring to FIG. 3, BMS 16 may include at least one processing circuitry 46, such as a processor 48 (e.g., processing unit) and memory 50, battery management unit 52, and communication interface 54. Processing circuitry 46 is included in BMS 16 and may have storage and / or processing capabilities. The processing circuitry 46 may include processor 48 and memory 50. In particular, in addition to or instead of a processor 48, such as a central processing unit, and memory, the processing circuitry 46 may comprise integrated circuitry for processing and / or control, e.g., one or more processors and / or processor cores and / or FPGAs (Field Programmable Gate Array) and / or ASICs (Application Specific Integrated Circuitry) adapted to execute instructions. The processor 48 may be configured to access (e.g., write to and / or read from) memory 50, which may comprise any kind of volatile and / or nonvolatile memory, e.g., cache and / or buffer memory and / or RAM (Random Access Memory) and / or Read-Only Memory and / or optical memory and / or EPROM (Erasable Programmable Read-Only Memory).

[0065] Processing circuitry 46 may be configured to control any of the methods and / or processes described herein and / or to cause such methods, and / or processes to be performed, e.g., by BMS 16 and / or battery 10. Processor 48 corresponds to one or more processors 48 for performing battery 10 functions described herein. Memory 50 may be configured to store data, programmatic software code and / or other information described herein. In some embodiments, software may include instructions that, when executed by the processor 48 and / or processing circuitry 46, causes the processor 48 and / or processing circuitry 46 to perform the processes described herein. The instructions may be software associated with BMS 16 and / or battery 10. Further, battery management unit 52 may be configured to perform any of the steps and / or methods and / or functions and / or processes and / or features of the present disclosure, e.g., by BMS 16 and / or battery 10. Communication interface 54 may be any interface arranged / configured to connect to (and / or communicate with) any other device and / or component of battery 10 such as another BMS 16, cloud network 32, server 34, vehicle 36, and / or any device by wireless / wired communication, e.g., using any communication protocol. Communication interface 54 may be in communication with any of the components of battery 10, such as processing circuitry 46, processor 48, memory 50, and / or battery management unit 52.

[0066] In a nonlimiting example, BMS 16 is configured to determine (i.e., capture, measure, read, etc.) data including battery cell data and / or battery cell parameters, e.g., via processing circuitry 46 and / or communication interface 54 and / or battery cells 14. More specifically, BMS 16 may be configured to determine a state of health of a battery cell 14 and / or battery 10 and / or a temperature of the battery 10 by using a connection that is established between BMS 16 and the battery cell 14 and the sensor 27 and / or the sensor 28. Further, BMS 16 may be further configured to analyze the data. BMS 16 may also be configured to communicate the analyzed data or any other data, e.g., transmit / receive data which may include battery cell data and / or battery cell parameters, e.g., via communication interface 54. The analyzed data or any other data may be transmitted to and / or received from another device, e.g., that may be connected to BMS 16 such as via communication interface 54. Communicating data may be performed using a protocol such as CAN and / or LIN to Bluetooth via communication interface 54. That is, communicating data is not limited to wired connections / protocols and may also include the use of any wireless connections / protocols to communicate to one or more de vices / sy stems. The arrangement described above is beneficial at least because battery 10 is capable of capture data such as battery cell data (e.g., lead acid battery cell data) and / or process the data and / or communicate the data for monitoring and / failure prediction of battery cells and other battery components.

[0067] In some embodiments, BMS 16 includes at least one of sensor 27 and sensor 28 configured to perform the corresponding functions described herein.

[0068] Also, any of the cloud network 32, the server 34 and the vehicle 36 may include hardware and / or software which is similar to the BMS 16 of FIG. 3 and may perform similar functions as well.

[0069] FIG. 4 shows an example battery including one or more apertures 25 (e.g., apertures 25a, 25b, 25c). More specifically, housing 12 may include apertures 25 arranged to receive probes 26 (e.g., probes 26a, 26b, 26c) and expose probes 26 to the interior of battery 10. Sensors 27 (e.g., sensors 27a, 27b, 27c) are also shown. Each probe 26 may include at least one sensor 27 and the sensor 27 may be received within the aperture 25 which may expose the sensor 27 to the interior of the battery 10. The sensor 27 may be located in the interior of the battery 10 in various locations including in or proximate one or more cells 14. The location of the apertures 25 may be determined based on temperature profiles, models, predictions of temperature, etc. The apertures 25 may be placed in a variety of different locations within the housing 12, and the probes 26 and the one sensor 27 that is associated with the probe 26 may be inserted into the housing 12 in various locations. The location and size of these apertures 25 may be based on a variety of different factors including, but not limited to the type of battery 10 that is being used, the size of the battery 10 being used, the climate that the battery 10 is being used in, and a variety of other factors. Further, probes 26 and / or sensors 27 may be coupled to at least one cell 14 (and / or its elements).

[0070] As a non-limiting example, the location of the various apertures 25 may be determined based upon certain determined parameters. For example, a first location of aperture 25a may be determined based upon l / 6th of the total height from the bottom of the battery 10 plus l / 4th of the 2 / 3rd height region. In other words, the first location of aperture 25a may be at a height of H / 6 + H*(2 / 3) / 4 from the bottom of the battery 10. Also, a second location of aperture 25b may be located at l / 6th of the total height from the bottom of the battery 10 plus 2 / 4th (or 1 / 2) of the 2nd and / or 3rd height region. So, it’s at a height of H / 6 + H*(2 / 3) / 2 from the bottom of the battery 10. Further, a third location of aperture 25c may be located at l / 6th of the total height from the bottom of the battery 10 plus 3 / 4th of the 2 / 3rd height region. Therefore, it is at a height of H / 6 + H*(2 / 3)*3 / 4 from the bottom of the battery 10. This example allows the even distribution of the measurement points within the middle 2 / 3rd height region of the battery 10, while leaving the top and bottom l / 6th regions of the battery 10 free. The measurement may occur on the plate 40 of the battery 10. It will be understood that these are example locations, but various determined parameters may be used to identify various locations of the apertures 25 within the battery 10.

[0071] FIG. 5 shows a view of an example battery 10 including one or more probes 26 (i.e., probes 26a, 26b, 26c, 26d, 26e, 26f) where the one or more probes 26 may be inserted in apertures 25 of housing 12 so that the probes 26 are inside the battery 10 and can be in close proximity with or touching various internal components of the battery 10 such as the components of a cell 14. In this nonlimiting example, each probe has a corresponding sensor 27 (i.e., sensor 27a, 27b, 27c, 27d, Tie, 27f). The cell of the battery may include plates, separators, etc. In one example, the battery 10 may be an absorbed glass mat (“AGM”) battery including cells 14, which may include a glass mat separator 38. The glass mat separator 38 may be a thin absorbent mat that is placed between the battery’s positive and negative plates which creates a more efficient and controlled flow of ions during charging and discharging cycles within the battery 10. The glass matt separator 38 may have a liquid electrolyte, such as sulfuric acid, that is absorbed into the glass matt separator 38. This liquid electrolyte may assist with the chemical reactions that occur during the operation of the battery 10 to allow the flow of electrons and conversion of chemical energy into electrical energy. Further, cell 14 of the battery 10 may include a plurality of positive and negative plates 40 inside the battery 10 (collectively referred to as plates 40). The plurality of positive and negative plates 40 may be made from lead and may be coated with materials such as lead dioxide on the positive plate 40 and sponge lead on the negative plate 40. The plurality of positive and negative plates 40 may provide surface area for the chemical reactions to occur which allows for the storage and release of energy. The interior of the battery 10 may also include at least one separator 44. The separator 44 may provide a physical barrier between the positive and negative plates 40. The use of the separator 44 may help improve battery charge acceptance and may be in the shape of an envelope so that the separator 44 can envelope at least one of the positive and negative plates 40 within the battery 10. The probes 26 may be electrically connected to BMS 16 or other components of system 30 such as to measure the temperature of each location of battery 10 where each one of the probes 26 is placed. Each of the probes 26 may be placed in specific locations within the battery 10 to measure the temperature in various locations throughout the battery 10. As shown in FIG. 4, the sensor 27 may be inserted with the probe 26 through the housing 12 and into the battery 10. Each sensor 27 that is associated with probe 26 may be placed in close proximity to or in physical contact with various components of the inside of the battery 10. Once the probe 26 enters into the inside of the housing 12, the sensor 27 that is associated with the probe 26 can be placed at a particular location inside the battery 10. For example, the sensor 27 that is associated with each probe 26 may be placed inside the battery 10 and where multiple probes 26 are used, each sensor 27 may be placed at different locations.

[0072] As a non-limiting example, the sensor 27 may be a temperature sensor and in communication with the BMS 16 to measure various locations inside the battery 10. Probe 26a may be inserted into the battery 10 though the aperture 25 and sensor 27a may be disposed proximate to or in contact with the glass matt separator 38. Probe 26b may be inserted into the battery though the aperture 25 and sensor 27b may be disposed proximate to or in contact with the separator 44. Probe 26c may be inserted into the battery though the aperture 25 and sensor 27c may be disposed proximate to or in contact with positive or negative plate 40. Probe 26d may be inserted into the battery though the aperture 25 and sensor 27d may be disposed proximate to or in contact with separator 44. Probe 26e may be inserted into the battery though the aperture 25 and sensor 27e may be disposed proximate to or in contact with at least one positive or negative plate 40. Probe 26f may be inserted into the battery though the aperture 25 and sensor 28f may be disposed proximate to or in contact with separator 44.

[0073] In some embodiments, measuring various temperatures inside the battery 10 can be used to create temperature profiles from measurements taken at various locations in a battery 10. The measurements can be made inside the battery 10 from probes 26 and sensors 27 that are placed in similar locations inside the battery 10. The probes 26 and sensors 27 may be placed in different locations inside the battery 10 to take the measurements. A first model, such as the FEA thermal model, may be developed based on one or more battery characteristics (e.g., AGM battery designs). In this nonlimiting example, the FEA thermal model is a mathematical and computerized technique that uses simulations to predict how an object, such as an AGM battery, will behave under various physical conditions based upon calculations made with the FEA thermal model. The FEA thermal model may be generally where the air around the battery may be referred to as the general environment of the FEA model. As another non-limiting example of a model, the Computational Fluid Dynamics (CFD) model may include information associated with air flow around the battery that is used to determine the FEA model. CFD may be referred to as a CFD thermal model. The CFD may help calibrate any measurements and be used to reduce complexity with the FEA model. The CFD model may be used to identify the location where the sensor 28 can be placed. The temperature at the location of sensor 28 may be compared (e.g., by BMS 16) with the cell temperature to predict the battery performance.

[0074] In some embodiments, a second model, such as the ROM, can be implemented for the purpose of improving the algorithm accuracy given the environmental temperature distribution and common usage scenarios. As a non-limiting example, the ROM may be used to integrate the CFD and / or the FEA model(s) into the system simulation. The ROM may be used as a mathematical technique that reduces the complexity of the mathematical model, but not the physical one. The ROM may do this by reducing the number of equations or variables in the model which can significantly speed up computations, especially for systems with many degrees of freedom. A ROM may capture the essential behavior of the original model while ignoring the details that have less impact on the results. Further, the FEA model is the physical model, and when the geometry is simplified and the whole stack of multi components are combined into one block or box, this model can be used for recalculating one or more material properties. Further, use of the FEA model and other models may reduce complexity in the model and allow prediction of the cell temperature as a whole.

[0075] In some embodiments, a ROM may be a model that is used to capture certain information and determine the dominant effects of the system being studied, e.g., the battery 10, using minimal computational resources. The ROM model may be based upon at least one condition that is associated with the battery 10. The at least one condition that may be associated with the battery can be a variety of different environmental conditions and the at least one condition may include but it not limited to temperature, pressure, and humidity in the environment.

[0076] Further, one or more battery behaviors may be determined such as how the internal temperature of the battery 10 responds to temperatures of an environment that is exterior to the battery 10. This may include how the internal temperature of the battery 10 responds to temperatures of an environment that is exterior to the battery 10 at various locations within the battery 10. For example, the temperature of the external environment may be varied to a first value, e.g., -25 C, and later increased to a second value, e.g., +25 C. Temperatures at different locations within the battery 10 (e.g., top, middle, and bottom of a cell 14 (i.e., a first cell), and top, middle, and bottom of another cell 14 (i.e., a second cell)) may be measured and temperature profiles created. The temperature associated with other locations of the battery 10 (including in or near various components inside the battery 10 including in the BMS 16, the monitoring connector 18, the negative terminal 22a, the positive terminal 22b, the glass matt separator 38, the plates 40, and any separators 44, etc.) may be measured and / or determined. As a non-limiting example, the temperature in the cover 20 of the battery 10 may be determined as well as the temperature of other components of battery 10 which may include the post assemblies 35 which may comprise posts, mini posts, etc. That is, the location for measurement of temperature and the location of sensor 28 may be any location within the battery 10.

[0077] The temperature profiles may be used for validating a model and / or for implementation of a model. In some other embodiments, the temperature values, models, and temperature profile may be used to determine an error associated with the measurement of the temperature at various location within the battery. The error may be further used to improve the model. For example, a combination of locations of temperature measurements may produce a first error, while a second combination of location of temperature measurements may produce a second error. Errors may be compared to correct and / or optimize the model and / or determine an additional model that may be more accurate.

[0078] In a nonlimiting example, battery 10 is placed in a simulated operating environment. The temperature of the environment may be varied to a first value and then raised to a second value such as value that represent expected temperatures in the engine compartment of a vehicle comprising battery 10. Temperature profiles may be generated and used to determine how the performance of the battery 10 is affected based on the external temperature and any changes in the external temperature. Models may be generated by varying the locations of the probes 24 or placing multiple probes 24 at various locations on / in the battery 10. The models may be used to determine the best location to measure temperature (e.g., in a produced battery similar to the testing battery) and to predict battery performance.

[0079] In some embodiments, reliability of a temperature probe / sensor in battery 10 component (such as in an AGM battery cover 20) as representative of the internal battery temperature is verified. Further, simulations of thermal distribution within battery 10, e.g., as a steppingstone towards other battery designs, are validated. Further, optimal location for battery temperature measurement can be determined. As another example, temperature shifts (e.g., temperature shifts from 25 °C to 50 °C, and temperature shifts from 75° C to -40 °C. More specifically, simulation results in comparison to the experimental results are shown, where legend “mech_cell”, “fluent_cell” refers to simulation results using two different simulation tools, and the ex_cell references the measured results. Based on the simulation results, in responding to various environmental temperature scenarios, the battery temperature probe / sensor measurement error can be determined / estimated. The battery temperature probe / sensor measurement error may impact the accuracy of the state of health (“SoH”) and state of function (SoF) estimation. That is, taking the error into account may produce a model that is more accurate than conventional models.

[0080] In some embodiments, a battery 10 may have different temperatures. For example, the temperature of a cell 14 that is located in the middle of a cell group may have higher temperature than a cell 14 that is not in the middle. Alternatively, the temperature of a cell 14 that is located in the middle of a cell group may have a lower temperature than a cell 14 that is not in the middle. That is, battery 10 may have different temperature values throughout the interior space, thereby creating a thermal distribution. Probes 26 can be positioned in different battery locations e.g., based on the thermal distribution which may be previously determined.

[0081] FIG. 6 shows an example implementation according to some embodiments. A first battery 10a (e.g., testing battery), a second battery 10b (e.g., production battery), and server 34 are shown where each component may be in communication with one another. In some embodiments, a first battery 10a, probes 26, and sensors 27 are used to determine a first model. A second model may be determined based on the first model, and the sensor location of one or more sensors 28 can be determined based on the first model and / or the second model. For example, any component shown in FIG. 2 may configured to determine the first model using data and / or measurements associated with sensors 27, determine the second model based on the first model and / or the data and / or the measurements, and determine the sensor location of one or more sensors 28 (e.g., location of sensor 28 on production battery 10b). In a more specific example, BMS 16 may obtain the data and / or measurements directly or via any other component of system 30, determine the first and second models, and the sensor location. Similarly, server 34 may obtain the data and / or measurements directly or via any other component of system 30, determine the first and second models, and the sensor location.

[0082] The sensor location, sensor information, and sensor location information (and / or first model and / or second model) may be stored in a configuration that may be provided to any component of system 30, such as another BMS 16 of a second battery 10b. The second battery 10b may be assembled with one or more sensors 28, each one at a predetermined location based on a set of predetermined locations or at the sensor locations specified by the configuration. The BMS 16 of the second battery 10b may be configured to receive the configuration including the sensor location (and / or first model and / or second model) and use the configuration to select at least one sensor 28 of the one or more sensors 28 that were determined using the first battery 10a. In one or more embodiments, BMS 16b is configured to activate at least one sensor 28 and / or a corresponding electrical path 56 based on the selection, where activating may refer to energizing, enabling, closing a circuit element / component, etc.

[0083] In some embodiments, BMS 16 is electrically coupled to sensor 28a via path 56a, BMS 16 is electrically coupled to sensor 28b via path 56b, and BMS 16 is electrically coupled to sensor 28c via path 56c. Further, BMS 16 may be configured to activate at least one of the paths 56a, 56b, 56c (collectively referred to as path 56) based on a configuration, or the contents of the configuration. Path 56 may refer to a conductor or electric / electronic circuit element / component, e.g., conductors, relays, switches, etc. Each sensor 28 is shown as being connected to the BMS 16 via separate paths 56. However, the embodiments of the present disclosure are not limited as such, and a path 56 may be used for more than one sensor 28, such as in the case of sensors configured to communicate using a protocol supporting such arrangement (e.g., master-slave protocol).

[0084] In some embodiments, the first battery 10a is a test battery, while the second battery 10b is a production battery. Thus, the second battery 10b (production battery) may include one or more sensors 28 that are selectable or that can be activated by BMS 16 to measure the temperature of an area or space within the battery that is determined based on the first model, second model, and temperature measurements made via probes 26 and sensors 27. In some embodiments, battery 10b is assembled with only one sensor 28, and the BMS 16 may activate a circuit element or path 56 based on the configuration.

[0085] In some embodiments, the BMS 16 of the second battery 10b may be configured to receive a first configuration, including a first sensor location for a sensor 28. However, the second battery 10 may be configurable and adaptable to various situations, conditions, environments, etc., where the BMS 16 of the second battery 10 may obtain a second configuration different from the first configuration, including data, temperature measurements, a third model, a fourth model, and / or sensor location information. The BMS 16 of the second battery 10b may be configured to determine a sensor location that may be different from the sensor location determined using the first configuration. The BMS 16 may select, based on the second configuration, a sensor 28 (e.g., previously assembled in the second battery 10b) that may be different from the selected sensor 28 of the first configuration.

[0086] In some other embodiments, BMS 16 of the second battery may use one or more configurations of a plurality of configurations to determine sensor locations of sensors 28 based on an indication received from cloud network 32 and / or server 34 and / or vehicle 36. In some embodiments, the determined sensor locations is based on another measurement performed by BMS 16 which may be associated with any components of the battery 10. In some other embodiments, the determined sensor locations is based on predetermined schedule of configurations, e.g., to respond to seasonal variations of environmental parameters, battery parameters, vehicle parameters, or to respond to different use cases, etc. In some embodiments, the first battery 10a and the second battery 10b are the same battery, e.g., where the testing is performed, and sensors 27, 28 are used or placed in the same battery.

[0087] In some embodiments, a FEA model is used to determine a temperature distribution. The nodes associated with parts, subparts, or elements that are the result of the logical division of battery 10 and any other elements, parameters, functions associated with the FEA model may be used to determine a plurality of temperatures values, where a subset of the temperature values corresponds to a node. The subset of values corresponding to a node may be used to determine whether sensor 28 should be placed in an area corresponding to the node or logical division. For example, where the subset of values indicates higher temperature values than the temperature values of other subsets, the sensor 28 may be located in the area associated with the node that corresponds to the subset of values indicating higher temperature, such that the area of higher temperature is used to measure temperature via BMS 16 and / or sensor 28. The temperature measured via sensor 28 may be used to prevent or predict catastrophic failures of battery 10. Other criteria for selection of sensor location may include lower temperature values with respect to other nodes, temperature differential between two or more areas corresponding to different nodes, heat transfer, measure temperature maximums and minima, and any other statistical parameter associated with temperature.

[0088] Now referring to FIG. 7, an example method for estimation of temperature distribution of a battery is shown. One or more of the blocks and / or steps described may be performed by any components of system 30 (e.g., BMS 16). The battery 10 includes BMS 16. The method may be implemented by the BMS 16. The battery 10 has a shell 29 that includes a housing 12 and a cover 20. The housing 12 and the cover 20 of the shell 29 define an interior space 31. The method includes determining (S100) at least one of a finite element analysis (FEA) thermal model and a computational fluid dynamic (CFD) thermal model based on at least one temperature value associated with a temperature of the interior space 31. The method also includes determining (S102) a reduced order model (ROM) based on at least one of the FEA thermal model and the CFD thermal model, and determining a location inside the battery for placement of a battery sensor 28 configurable to measure temperature. The location is determined (S104) based upon at least one of the FEA thermal model, the CFD thermal model, and the ROM.

[0089] In some embodiments, the battery 10 further includes a plurality of cells 14 housed within the interior space 31 , and the at least one temperature value is associated with the temperature of at least one cell of the plurality of cells 14.

[0090] In some other embodiments, the ROM is further determined based at least on one condition associated with the battery 10, where the at least one condition associated with the battery 10 is at least one of the temperature, a pressure, and a humidity.

[0091] In some embodiments, the battery is an absorbent glass mat (AGM) battery having at least one glass mat separator 44 in the interior space 31 , and the at least one temperature value is associated with the temperature of the glass mat separator 44.

[0092] In some other embodiments, the location inside the battery 10 for placement of the battery sensor 28 is further based on the temperature of the glass mat separator 44.

[0093] In some embodiments, the BMS 16 may perform actions based on the location, the FEA thermal model, the CFD thermal model, and the ROM. Actions may include transmitting signaling to other components including reports, indications, configurations, information, etc., associated with the location, the sensor, the FEA thermal model, the CFD thermal model, and the ROM. Other actions may include triggering other components of system 30 to perform similar actions or other actions.

[0094] In some other embodiments, the method further includes performing, by the BMS 16, at least one action based on at least one of the location, the FEA thermal model, the CFD thermal model, and the ROM.

[0095] In some embodiments, the at least one action includes at least one of: (A) determining at least one of a report, an indication, a configuration, and a message comprising information associated with the location, the sensor, the FEA thermal model, the CFD thermal model, and the ROM; (B) transmitting signaling including at last one of the report, the indication, the configuration, and the message; (C) activating the battery sensor 28; and (D) deactivating the battery sensor 28. Other actions may include the BMS 16 enabling or disabling a BMS operating mode (e.g., sleep mode to perform BMS functions at a reduced rate, active mode to perform BMS functions at a greater rate than the reduced rate, etc.), enabling or disabling a battery operating mode (e.g., enabling or disabling cells 14, the battery 10, etc.), predict that the battery will perform or fail to perform according to a set of battery performance requirements, transmit an indication of a battery state based on the prediction, etc.

[0096] In some other embodiments, the BMS 16 is configured to communicate with at least one of a server 34 and a vehicle 36, the transmitted signaling triggering at least one of the server 34 and the vehicle 36 to perform at least one other action. For example, server 34 may determine any model described in the present disclosure and / or battery sensor location, determine a configuration using the model, transmit the configuration to another BMS 16 and cause the other BMS 16 to be configured with the configuration and perform actions according to the configuration. The vehicle 36 may perform another action such as displaying an alert for the driver regarding a temperature at the location of the battery sensor 28, cause the vehicle 36 to operate according to a temperature value measured by the battery sensor 28, activate another battery 10 for use by the vehicle 36, etc.

[0097] In some embodiments, the method may be referred to as a thermal simulation method that can be implemented in BMS 16 to estimate the battery temperature distribution based on one or more temperature sensor measurements within the battery 10. The thermal simulation method may enable the estimation of the battery temperature distribution inside the battery housing at multiple internal cell locations, leading to improved battery performance and life prediction.

[0098] In some embodiments, although the shell 29 is described as comprising housing 12 and the cover 20, the embodiments are not limited as such, and the shell 29 may include only the housing 12 that defines the interior space 31. The housing 12 may have an outer surface exposed to an exterior environment 33.

[0099] FIG. 8 shows another example method for determining a distribution of temperature values and / or location of a sensor associated with a battery 10 is described. One or more of the blocks and / or steps described may be performed by any components of system 30 (e.g., BMS 16). The battery 10 may have a shell 29 defining an interior space 31 ), with the shell 29 having an outer surface 37 exposed to an exterior environment 33. The battery 10 includes a plurality of cells 14 housed within the interior space 31. The shell 29 includes a plurality of apertures 25. The method may include inserting (Block S106) a plurality of probes 26 into the interior space 31 of the battery 10 through a plurality of apertures 25, where each probe 26 from the plurality of probes 26 has at least one sensor 27 that is configured to measure a temperature of the interior space 31. The method may further include determining (Block S108) at least one temperature value associated with at least one sensor 27 on each probe 26 from the plurality of probes 26, determining (Block S 110) at least one of a finite element analysis (FEA) thermal model and a computational fluid dynamic (CFD) thermal model based on the at least one temperature value and an exterior environment temperature, and determining (Block SI 12) a reduced order model (ROM) based on at least one of the FEA thermal model and the CFD thermal model. Further, the method may also include determining (Block SI 14) a location inside the battery 10 for placement of a battery sensor 28 configurable to measure temperature based upon at least one of the FEA thermal model, the CFD thermal model, and the ROM.

[0100] In some embodiments, the ROM is further determined based at least on one condition associated with the battery 10, the at least one condition associated with the battery 10 is at least one of the temperature, a pressure, and a humidity.

[0101] In some embodiments, the plurality of probes 26 comprises nine separate probes 26.

[0102] In some embodiments, each probe 26 is inserted into a different cell 14 of the battery 10.

[0103] In some embodiments, the method further comprises performing, by each sensor 27, one or more measurements of the at least one temperature value inside the battery 10.

[0104] In some embodiments, the method further comprises transmitting an indication indicating the measurement of the at least one temperature value associated with at least one sensor on each probe 26 from the plurality of probes 26.

[0105] In some embodiments, the measuring at least one temperature value associated with the at least one sensor 27 on each probe 26 from the plurality of probes 26 further includes measuring a plurality of temperature values associated with the at least one sensor 27 on each probe 26 from the plurality of probes 26 over a twenty-four hour period.

[0106] In some embodiments, the battery is an absorbent glass mat (AGM) battery having at least one glass mat separator 38 in the interior space 31, and the method further includes inserting one probe from the plurality of probes 26 into the interior space 31 of the battery 10 through one aperture 25 from the plurality of apertures 25, the corresponding sensor 27 being placed proximate to the at least one glass mat separator 38 and being arranged to measure the temperature of the glass mat separator 38.

[0107] In some embodiments, the location inside the battery for placement of the battery sensor is further based on the temperature of the glass mat separator 38. In some other embodiments, the insertion of multiple probes 26 with sensors 27 into the battery 10 to measure temperature distribution serves the purpose of developing and validating the appropriate FEA, CFD, or ROM models against thermal simulation results.

[0108] As will be appreciated by one of skill in the art, the concepts described herein may be embodied as a method, data processing system, computer program product and / or computer storage media storing an executable computer program. Accordingly, the concepts described herein may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects all generally referred to herein as a “circuit” or “module.” Any process, step, action and / or functionality described herein may be performed by, and / or associated to, a corresponding module, which may be implemented in software and / or firmware and / or hardware. Furthermore, the disclosure may take the form of a computer program product on a tangible computer usable storage medium having computer program code embodied in the medium that can be executed by a computer. Any suitable tangible computer readable medium may be utilized including hard disks, CD-ROMs, electronic storage devices, optical storage devices, or magnetic storage devices.

[0109] Some embodiments may be described herein with reference to flowchart illustrations and / or block diagrams of methods, systems and computer program products. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer (to thereby create a special purpose computer), special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0110] These computer program instructions may also be stored in a computer readable memory or storage medium that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer readable memory produce an article of manufacture including instruction means which implement the function / act specified in the flowchart and / or block diagram block or blocks.

[0111] The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0112] It is to be understood that the functions / acts noted in the blocks may occur out of the order noted in the operational illustrations. For example, two blocks shown in succession may in fact be executed substantially concurrently or the blocks may sometimes be executed in the reverse order, depending upon the functionality / acts involved. Although some of the diagrams include arrows on communication paths to show a primary direction of communication, it is to be understood that communication may occur in the opposite direction to the depicted arrows.

[0113] Computer program code for carrying out operations of the concepts described herein may be written in an object oriented programming language such as Python, Java® or C++. However, the computer program code for carrying out operations of the disclosure may also be written in conventional procedural programming languages, such as the "C" programming language. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer. In the latter scenario, the remote computer may be connected to the user's computer through a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).

[0114] Many different embodiments have been disclosed herein, in connection with the above description and the drawings. It will be understood that it would be unduly repetitious and obfuscating to literally describe and illustrate every combination and subcombination of these embodiments. Accordingly, all embodiments can be combined in any way and / or combination, and the present specification, including the drawings, shall be construed to constitute a complete written description of all combinations and subcombinations of the embodiments described herein, and of the manner and process of making and using them, and shall support claims to any such combination or subcombination.

[0115] It is understood that all specification values shown and described herein are nonlimiting examples for implementations of batteries 10, cells 14, BMS 16, cloud network 32, server 34, and / or vehicle 36 constructed in accordance with the principles of the disclosure provided herein. It will be appreciated by persons skilled in the art that the present embodiments are not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings and following claims.

Claims

Claims:

1. A method for estimation of temperature distribution of a battery (10) comprising a battery management system, BMS, (16), the method being implemented by the BMS (16), the battery (10) having a shell (29) including a housing (12) and a cover (20), the housing (12) and the cover (20) of the shell (29) defining an interior space (31), the method comprising: determining (S100) at least one of a finite element analysis, FEA, thermal model and a computational fluid dynamic, CFD, thermal model based on at least one temperature value associated with a temperature of the interior space (31); determining (S102) a reduced order model, ROM, based on at least one of the FEA thermal model and the CFD thermal model; and determining (SI 04) a location inside the battery (10) for placement of a battery sensor (28) configurable to measure temperature, the location being determined based upon at least one of the FEA thermal model, the CFD thermal model, and the ROM.

2. The method of Claim 1, wherein the battery (10) further includes a plurality of cells (14) housed within the interior space (31), the at least one temperature value being associated with the temperature of at least one cell (14) of the plurality of cells (14).

3. The method of any one of Claims 1 and 2, wherein the ROM is further determined based at least on one condition associated with the battery (10), the at least one condition associated with the battery (10) is at least one of the temperature, a pressure, and a humidity.

4. The method of any one of Claims 1-4, wherein the battery (10) is an absorbent glass mat, AGM, battery having at least one glass mat separator (44) in the interior space (31), and the at least one temperature value is associated with the temperature of the glass mat separator (44).

5. The method of Claim 4, wherein the location inside the battery (10) for placement of the battery sensor (28) is further based on the temperature of the glass mat separator (44).

6. The method of any one of the Claims 1-5, wherein the method further includes: performing, by the BMS (16), at least one action based on at least one of the location, the FEA thermal model, the CFD thermal model, and the ROM.

7. The method of Claim 6, wherein the at least one action includes at least one of: determining at least one of a report, an indication, a configuration, and a message comprising information associated with the location, the sensor, the FEA thermal model, the CFD thermal model, and the ROM; transmitting signaling including at last one of the report, the indication, the configuration, and the message; activating the battery sensor (28); and deactivating the battery sensor (28).

8. The method of Claim 7, wherein the BMS (16) is configured to communicate with at least one of a server (34) and a vehicle (36), the transmitted signaling triggering at least one of the server (34) and the vehicle (36) to perform at least one other action.

9. A method for determining a distribution of temperature values inside a battery (10), the battery (10) having a shell (29) defining an interior space (31), with the shell (29) having an outer surface (37) exposed to an exterior environment (33), the battery (10) comprising a plurality of cells (14) housed within the interior space (31), the shell (29) comprising a plurality of apertures (25), the method comprising: inserting (SI 06) a plurality of probes (26) into the interior space (31) of the battery (10) through a plurality of apertures (25), each probe (26) from the plurality of probes (26) having at least one sensor (27) that is configured to measure a temperature of the interior space (31); determining (S108) at least one temperature value associated with at least one sensor (27) on each probe (26) from the plurality of probes (26); determining (SI 10) at least one of a finite element analysis, FEA, thermal model and a computational fluid dynamic, CFD, thermal model based on the at least one temperature value and an exterior environment temperature;determining (SI 12) a reduced order model, ROM, based on at least one of the FEA thermal model and the CFD thermal model; and determining (SI 14) a location inside the battery (10) for placement of a battery sensor (28) configurable to measure temperature based upon at least one of the FEA thermal model, the CFD thermal model, and the ROM.

10. The method of Claim 9, wherein the ROM is further determined based at least on one condition associated with the battery (10), the at least one condition associated with the battery (10) is at least one of the temperature, a pressure, and a humidity.

11. The method of any one of Claims 9 and 10, wherein the plurality of probes (26) comprises nine separate probes (26).

12. The method of any one of Claims 9-11, wherein each probe (26) is inserted into a different cell (14) of the battery (10).

13. The method of any one of Claims 9-12, the method further comprising: performing, by each sensor (27), one or more measurements of the at least one temperature value inside the battery (10).

14. The method of any one of Claims 9-13, the method further comprising: transmitting an indication indicating the measurement of the at least one temperature value associated with at least one sensor (27) on each probe (26) from the plurality of probes (26).

15. The method of any one of Claims 9-14, wherein the measuring at least one temperature value associated with the at least one sensor (27) on each probe (26) from the plurality of probes (26) further includes measuring a plurality of temperature values associated with the at least one sensor (27) on each probe (26) from the plurality of probes (26) over a twenty-four hour period.

16. The method of any one of Claims 9-15, wherein the battery (10) is an absorbent glass mat, AGM, battery having at least one glass mat separator (44) in the interior space (31), and the method further includes:inserting one probe (26) from the plurality of probes (26) into the interior space (31) of the battery (10) through one aperture (25) from the plurality of apertures (25), the corresponding sensor (27) being placed proximate to the at least one glass mat separator (44) and being arranged to measure the temperature of the glass mat separator (44).

17. The method of Claim 16, wherein the location inside the battery (10) for placement of the battery sensor (28) is further based on the temperature of the glass mat separator (44).

18. A battery (10) comprising : a battery management system, BMS (16); a shell (29) defining an interior space (31); a plurality of cells (14) housed within the interior space (31); and at least one sensor (28) in communication with the BMS (16), the at least one sensor (28) having a location within the battery (10) that is based upon at least one of a finite element analysis, FEA, thermal model, a computational fluid dynamic, CFD, thermal model, and a reduced order model, ROM, at least one of the FEA thermal model and the CFD thermal model being based on the at least one temperature value, the ROM being based on at least one of the FEA thermal model and the CFD thermal model, the at least one temperature value being associated with a temperature of the interior space (31) associated with at least one cell (14) from the plurality of cells (14).

19. The battery (10) of Claim 18, wherein the at least one sensor (28) includes a first sensor (28) and a second sensor (28), the first sensor (28) being associated with a first sensor location within the interior space (31), the second sensor (28) being associated with a second sensor location within the interior space (31).

20. The battery (10) of Claim 19, wherein the BMS (16) is configured to: obtain a first configuration comprising the FEA thermal model, the CFD, the ROM, and location information corresponding to the first sensor (28); obtain a second configuration comprising the FEA thermal model, the CFD, the ROM, and location information corresponding to the second sensor (28); and activate at least one of the first sensor (28) and the second sensor (28) based on the first configuration and the second configuration.

21. A battery (10) comprising: a battery management system, BMS (16); a shell (29) defining an interior space (31); and a first sensor (28) in communication with the BMS (16), the first sensor (28) having a first location within the battery (10) that is based upon at least one of a first finite element analysis, FEA, thermal model, a first computational fluid dynamic, CFD, thermal model, and a first reduced order model, ROM, the first FEA thermal model and the first CFD thermal model being based on a first temperature value, the first ROM being based on at least one of the first FEA thermal model and the first CFD thermal model, the first temperature value being associated with a first temperature of the interior space (31); and a second sensor (28) in communication with the BMS (16), the second sensor (28) having a second location within the battery (10) that is based upon at least one of a second FEA thermal model, a second CFD, and a second ROM, the second FEA thermal model and the second CFD being based on a second temperature value, the second ROM being based on at least one of the second FEA thermal model and the second CFD thermal model, the second temperature value being associated with a second temperature of the interior space (31); the BMS (16) being configured to: activate at least one of the first sensor (28) and a second sensor (28) based on at least one of the first FEA thermal model, the first CFD thermal model, the first ROM, the second FEA thermal model, the second CFD thermal model, and the second ROM.

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