Simulating environmental conditions on battery packs to test coolant performance

Abstract

Aspects of the present disclosure are related to systems and methods for performing at least one test to simulate at least one environmental condition on at least one battery pack. A controller can execute a test comprising applying a condition to a battery pack comprising (i) a plurality of battery cells and (ii) a coolant; receive, from a sensor, data regarding at least one parameter associated with at least one of the battery pack or the coolant; determine, using the data from the sensor, a classification of the coolant for use with the plurality of battery cells; and provide an output regarding the test based on the classification of the coolant.

Description

SIMULATING ENVIRONMENTAL CONDITIONS ON BATTERY PACKS TO TEST COOLANT PERFORMANCECROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Patent Application No. 63 / 558,579, titled “Simulating Environmental Conditions on Battery Packs to Test Coolant Performance,” filed February 27, 2024, which is incorporated herein by reference in its entirety.BACKGROUND[0002[ A battery pack may include a set of battery cells to store electrical energy for components coupled thereto. While operational, the battery pack can store additional electrical energy from another source by charging the battery cells. Conversely, the battery pack can provide electrical energy to the components by releasing the stored electrical energy from the battery cells. During the operations to charge or discharge the battery cells, the battery pack may experience internal resistance leading to a buildup of thermal heat and increased temperatures.SUMMARY

[0003] Aspects of the present disclosure are related to a system for performing at least one test to simulate at least one environmental condition on at least one battery pack. The system may include a controller having one or more processors coupled with memory. The controller can execute a test comprising applying a condition to a battery pack comprising (i) a plurality of battery cells and (ii) a coolant; receive, from a sensor, data regarding at least one parameter associated with at least one of the battery pack or the coolant; determine, using the data from the sensor, a classification of the coolant for use with the plurality of battery cells; and provide an output regarding the test based on the classification of the coolant.

[0004] In some embodiments, the controller can determine, based on the condition, an amount of electrical power to be provided through the battery pack and execute the test by causing a power supply to supply the amount of the electrical power through the battery packin accordance with the condition. In some embodiments, the controller can determine, based on the condition, an amount of the coolant of a coolant type to provide to the battery pack and execute the test by causing a coolant filler to provide the amount of the coolant of the coolant type to the battery pack in accordance with the condition.10005] In some embodiments, the controller can determine, based on the condition, a plurality of parameters defining at least one provided by an oscillator to the battery pack and execute the test by causing the oscillator to provide the at least one vibration to the battery pack in accordance with the plurality of parameters of the condition. In some embodiments, the controller can determine whether to execute a second test based on the data regarding the at least one parameter.

[0006] In some embodiments, the controller can determine, responsive to the data regarding the at least one parameter satisfying a criterion, the classification to approve the use of the coolant with the plurality of battery cells. In some embodiments, the controller can determine, responsive to the data regarding the at least one parameter not satisfying a criterion, the classification to reject the use of the coolant with the plurality of battery cells. In some embodiments, the data regarding the at least one parameter may include at least one of (i) a temperature within the battery pack, (ii) a temperature of at least one battery cell of the plurality of battery cells, (iii) a temperature of the gas within the battery pack, (iv) a temperature of the coolant, (v) a refractivity of the coolant, (vi) an electrical conductivity, (vii) a hydrogen concentration, (ix) a humidity within the battery pack, and (x) an amount of gases.

[0007] Aspects of the present disclosure are related to a method of performing at least one test to simulate at least one environmental condition on at least one battery pack. The method can include executing, by a controller, a test comprising applying a condition to a battery pack comprising (i) a plurality of battery cells and (ii) a coolant; receiving, by the controller, from a sensor, data regarding at least one parameter associated with at least one of the battery pack or the coolant; determining, by the controller and using the data from the sensor, a classification of the coolant for use with the plurality of battery cells; and providing, by the controller, an output regarding the test based on the classification of the coolant.

[0008] In some embodiments, the method may include determining, by the controller, based on the condition, an amount of electrical power to be provided through the battery pack. Executing the test may include causing a power supply to supply the amount of the electrical power through the battery pack in accordance with the condition. In some embodiments, the method may include determining, by the controller, based on the condition, an amount of the coolant of a coolant type to provide to the battery pack. Executing the test may include causing a coolant filler to provide the amount of the coolant of the coolant type to the battery pack in accordance with the condition.

[0009] In some embodiments, the method may include determining, by the controller, based on the condition, a plurality of parameters defining at least one vibration provided by an oscillator to the battery pack. Executing the test may include causing the oscillator to provide the at least one vibration to the battery pack in accordance with the plurality of parameters of the condition. In some embodiments, the method may include determining, by the controller and responsive to the data regarding the at least one parameter satisfying a criterion, the classification to approve the use of the coolant with the plurality of battery cells. In some embodiments, the method may include determining, by the controller and responsive to the data regarding the at least one parameter not satisfying a criterion, the classification to reject the use of the coolant with the plurality of battery cells.

[0010] Aspects of the present disclosure are related to a system for analyzing at least one battery pack. The system can include one or more processors structured to be coupled with a testing environment having a battery pack and a sensor. The one or more processors can: execute a test comprising applying a condition to the battery pack comprising (i) a plurality of battery cells and (ii) a coolant; receive, from the sensor, data regarding at least one parameter associated with at least one of the battery pack or the coolant; determine, using the data from the sensor, a classification of the coolant for use with the plurality of battery cells; and provide an output regarding the test based on the classification of the coolant.

[0011] In some embodiments, the one or more processors can: determine, based on the condition, an amount of electrical power to be provided through the battery pack; and execute the test by causing a power supply of the testing environment to supply the amount of the electrical power through the battery pack in accordance with the condition. In someembodiments, the one or more processors can: determine, based on the condition, an amount of the coolant of a coolant type to provide to the battery pack; and execute the test by causing a coolant filler of the testing environment to provide the amount of the coolant of the coolant type to the battery pack in accordance with the condition. In some embodiments, the one or more processors can: determine, based on the condition, a plurality of parameters defining at least one vibration provided by an oscillator of the testing environment to the battery pack; and execute the test by causing the oscillator to provide the at least one vibration to the battery pack in accordance with the plurality of parameters of the condition.

[0012] In some embodiments, the one or more processors can determine, responsive to the data regarding the at least one parameter satisfying a criterion, the classification to approve the use of the coolant with the plurality of battery cells. In some embodiments, the one or more processors can determine, responsive to the data regarding the at least one parameter not satisfying a criterion, the classification to reject the use of the coolant with the plurality of battery cells.

[0013] Numerous specific details are provided to impart a thorough understanding of embodiments of the subject matter of the present disclosure. The described features of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments and / or implementations. In this regard, one or more features of an aspect of the invention may be combined with one or more features of a different aspect of the invention. Moreover, additional features may be recognized in certain embodiments and / or implementations that may not be present in all embodiments or implementations.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements unless otherwise indicated, in which:

[0015] FIG. 1 depicts a block diagram of a system for performing tests to simulate environmental conditions on battery packs in accordance with an illustrative embodiment;

[0016] FIG. 2 depicts a block diagram of an environment for simulating various conditions on battery packs in accordance with an illustrative embodiment;

[0017] FIG. 3 depicts a block diagram of an apparatus for applying oscillations to a battery module to test coolant and battery performance in accordance with an illustrative embodiment;10018] FIGs. 4A-C depict flow diagrams of a process of simulating various conditions on battery packs in accordance with an illustrative embodiment; and

[0019] FIG. 5 depicts a flow diagram of a method of performing tests to simulate environmental conditions on battery packs in accordance with an illustrative embodiment.DETAILED DESCRIPTION

[0020] Following below are more detailed descriptions of various concepts related to and implementations of methods, apparatuses, and systems for performing tests on coolants using simulated environmental conditions on battery packs. The various concepts introduced above and discussed in greater detail below may be implemented in any number of ways, as the concepts described are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

[0021] A battery pack may include a set of battery cells for storing and providing electrical energy to components that are coupled with the battery pack. When operating, the battery pack may accept electrical energy for storage by charging the battery cells.Conversely, the battery pack may deliver electrical energy to other components by discharging the battery cells. In both scenarios, the battery pack may undergo increased thermal heat leading to higher temperatures. Heat may be generated within the battery cells due to internal resistance and other sources of resistive loss as well as due to the chemical reactions occurring within the battery cells during charging or discharging. Without any cooling mechanism, the battery pack may experience increased heating and eventually a thermal runaway event. Such thermal runaway events can result in cell venting and rendering the battery pack inoperable and causing irreparable damage, and thus shortening the lifespan of the battery cells and the overall battery pack.[0022| To cool the battery cells, a coolant may be provided to the battery pack to transfer thermal heat and reduce temperature. The coolants selected for provision may have low electrical conductivity (e.g., low ability to conduct electricity) and high thermal capacity (e.g., ability to hold heat while maintaining temperatures). Regarding electrical conductivity, there may be trade-offs associated with low electrical conductivity coolants that may be deployed in battery systems. For example, to achieve low electrical conductivity, additives used in coolants may be severely limited, with low conductivity coolants generally providing less robust corrosion protection and having shorter service life.

[0023] Tests may be performed to identify coolants that provide dependable operation while also achieving corrosion protection and longer service life. A coolant may be identified as dependable, for example, when the coolant is able to prevent thermal runaway by avoiding resistive heating and hydrogen generation in the battery pack after a coolant leak. The better the coolant is able to prevent thermal runaways, the more dependable the coolant may be deemed to be. One test may include a full battery pack flooding test. Under this approach, a battery pack may be flooded with coolant and then held under observation to determine whether any battery venting, thermal runaway, or thermal event occurs. This test, however, may be destructive and may not allow monitoring of leaked coolants or fluids as well as any resultant gases during testing. Another test may be a hot wire test. Under this approach, wire leads (e.g., a copper wire) may be coupled with a power supply and then placed in a vessel containing the coolant to be evaluated. The power supply may be turned on for a short duration, and the electrical conductivity of the coolant may be measured and the appearance of the wires may be observed. Lacking the inclusion of the battery pack, however, this test may be unable to test voltages at which the coolant may face. Furthermore, this test may be unable to simulate gases that may be produced during fluid leaks when in contact with the battery cells.

[0024] To address these and other technical challenges, an apparatus may be provided to permit testing of battery cells in the event of a fluid leak without producing a thermal event. A controller may be structured to be coupled with the apparatus, sensors, and other components to facilitate the running of the testing on the battery cells. The controller may monitor for a thermal event using sensor data, such as battery cell temperature, hydrogen gasconcentration, and leaked fluid conductivity, among others. The controller may stop the testing prior to the thermal event to prevent thermal damage to the battery cell or test equipment. The test may be used to formulate and identify coolants to provide reliable and robust operations in battery systems that are less susceptible or more able to prevent resistive heating and hydrogen generation preceding or in partial concurrence with onset thermal runaway events. The test may be also used to assess the configuration and design of battery systems, including battery cell chemistry, orientation, and form factor on thermal runaway parameters in the event of a fluid leak into the battery.

[0025] Referring now to FIG. 1, depicted is a block diagram of a system 100 for performing tests to simulate environmental conditions on battery packs. In brief overview, the system 100 may include at least one controller 105, at least one testing environment 110, and a set of sensors 115A-N (hereinafter generally referred to as sensors 115), among others. The testing environment 110 may include at least one battery pack 120, at least one coolant filler 125 to provide coolant 180, at least one oscillator 130, and at least one power supply 135, among others. The battery pack 120 may include a set of battery cells 140A-N (hereinafter generally referred to as battery cells 140) and at least one cell mounting device 145 (sometimes herein referred to as a base plate), among others. The controller 105 may include at least one processor 150 and at least one memory 155, among others. The memory 155 may include instructions. The instructions on the memory 155 may include at least one test administrator 160, at least one data collector 165, at least one performance evaluator 170, and at least one output handler 175, among others. The controller 105, the testing environment 110, and the set of sensors 115 may be communicatively coupled with one another.

[0026] The testing environment 110 can correspond to or can include a chamber, an enclosure, or a room to evaluate the performance of the coolant 180 provided to the battery pack 120. The testing environment 110 can be used to apply or provide environmental conditions to the coolant 180 and the battery cells 140 of the battery pack 120 to simulate real -world conditions or specific use case scenarios. The testing environment 110 can also provide isolation of the coolant 180 and the battery cells 140 of the battery pack 120 from external interference or contamination to maintain integrity of the environmental conditions.The testing environment 110 can correspond to an interior volume or space within which to arrange, situate, or otherwise dispose various components of the system 100. The components arranged, situated, or otherwise disposed in the testing environment 110 can include, for example, the set of sensors 115, the battery pack 120 (with the battery cells 140), the coolant filler 125, the oscillator 130, and the power supply 135, among others. The testing environment 110 can be communicatively coupled with the controller 105 to exchange measurement data and command signals.

[0027] The battery pack 120 can correspond to or include a housing to store, contain, or otherwise include the set of battery cells 140. The housing can define or include an interior volume or region within which to arrange, situate, or otherwise dispose the set of battery cells 140 and the cell mounting device 145. For instance, the battery pack 120 can correspond to an enclosed box for storing the set of battery cells 140 for evaluation. The housing for the battery pack 120 can at least partially separate or isolate the set of battery cells 140 from the exterior. The housing of the battery pack 120 itself can be comprised of any material, such as an electrically insulative material including a polymer (e.g., polyethylene (PE), polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE) or composite material (e.g., ceramic, glass, or rubber)). The battery pack 120 may be of any shape, such as prismatic or cylindrical. The battery pack 120 can have any dimensions, such as a height between 3 cm to 5000 cm, a width of 3 cm to 5000 cm , and a length of 5 cm to 2000 cm.| 0028 | The set of battery cells 140 can be disposed, situated, or otherwise arranged in the battery pack 120. The set of battery cells 140 can at least partially span the volume defined by the housing of the battery pack 120. The set of battery cells 140 can obtain, receive, or otherwise accept electrical power to be stored and maintained on the battery cells 140. For instance, an external power supply (e.g., the power supply 135) can provide electrical power to charge the battery cells 140. The set of battery cells 140 can convey, deliver, or otherwise provide electrical energy stored thereon to one or more components coupled thereto. The set of battery cells 140 of the battery pack 120 can be structured to be electrically coupled with one or more external components. For example, the battery cells 140 can discharge to provide electrical power to external components.

[0029] Each battery cell 140 may be of any type, such as a lithium-ion battery cell, a nickel-zinc battery cell, a zinc-bromine battery cell, a zinc-cerium battery cell, a sodiumsulfur battery cell, or a nickel-cadmium battery cell, among others. The set of battery cells 140 can be of any shape and dimension. For example, the battery cell 140 can be prismatic, with a circular, elliptical, rectangular, square, pentagonal, or a polygonal base, among others. The battery cells 140 can have a length (or height) ranging between 25-1000 mm, a width ranging between 25-1000 mm, and a thickness ranging between 2-200 mm, among others. There may be any number of battery cells 140 arranged within the battery pack 120, ranging from 1 to 5000. The battery cells 140 may be in any orientation or direction (e.g., with respect to positive or negative terminals) within the battery pack 120. For example, each battery cell 140 can be arranged such that a positive terminal is toward the top of the battery pack 120 while the negative terminal is toward the bottom of the battery pack 120, and vice- versa. The battery cells 140 can also be arranged, rotated, or oriented about a x, y, or z axis defined through the horizontal, longitudinal, or vertical plane of the battery pack 120 at any range of angles (e.g., 0 to 360 degrees).

[0030] The cell mounting device 145 can correspond to or define at least one side of the housing for the battery pack 120. For example, the cell mounting device 145 can correspond to a bottom, lateral side of the housing for the battery pack 120. The cell mounting device 145 can support the set of battery cells 140 within the battery pack 120. The set of battery cells 140 can be situated, disposed, or otherwise disposed along the cell mounting device 145 in the battery pack 120. For example, the set of battery cells 140 can at least partially span the volume defined by the housing of the battery pack 120 along an axis (e.g., a lateral axis) of the cell mounting device 145. The cell mounting device 145 can be of any shape and dimension. The shape of the cell mounting device 145 can at least partially correspond to the shape of the battery pack 120. The dimensions of the cell mounting device 145 can at least partially correspond to at least one of the dimensions (e.g., width or length) of the battery pack 120.

[0031] The cell mounting device 145 can be thermally coupled with the set of battery cells 140 within the battery pack 120. The cell mounting device 145 can dissipate or transfer thermal energy from within the battery pack 120 during the operation of the set of batterycells 140 (e.g., while charging or discharging). In some embodiments, the cell mounting device 145 can be a passive thermal management device to dissipate or transfer heat from the set of battery cells 140 during operation. For example, the cell mounting device 145 can be a heat spreader, a heat pipe, a heat sink, a heat shield, or a heat insulator, among others. The cell mounting device 145 can transfer heat from the set of battery cells 140 of the battery pack 120. In some embodiments, the cell mounting device 145 can be an active thermal management device. For example, the cell mounting device 145 can include a fan, a heat pump, a thermoelectric cooler, a heat exchanger, or a cold plate, among others. The active thermal management device can be powered by a separate power source.10032] The coolant filler 125 can manage, regulate, or otherwise control provision of the coolant 180 to the battery pack 120. The coolant filler 125 can be fluidly coupled with the interior volume of the battery pack 120. The coolant filler 125 can include one or more components to provide the coolant 180 to the battery pack 120 and to release the coolant 180 from the battery pack 120. The components of the coolant filler 125 can include, for example, a reservoir to store the coolant 180; at least one pump to pull the coolant 180 from the reservoir or into the reservoir; an inlet valve to regulate an inflow rate of the coolant 180 into the battery pack 120; an outlet valve to regulate an outflow rate of the coolant 180 from the battery pack 120; at least one heater (e.g., an electric heater, cartridge heater, or heat exchanger) to heat the coolant 180 and control the temperature of the coolant 180 when provided to the battery pack 120; at least one nozzle to introduce or add coolant with specific spray characteristics (e.g., droplet size, spray angle, density, velocity, pattern, and frequency); and one or more manifolds to fluidly couple the components with one another. The coolant 180 provided by the coolant filler 125 can be a fluid of any type. The coolant 180 may include, for example, a glycol mixture (e.g., ethylene glycol, diethylene glycol, or propylene glycol) with water. The coolant 180 can draw or transfer thermal energy (or heat) away from the battery cells 140 in the battery pack 120. The coolant filler 125 can be structured to be communicatively coupled with the controller 105.

[0033] The oscillator 130 can manage, regulate, or otherwise control provision of mechanical motion applied on the battery pack 120. The mechanical motion may include, for example, moving, shaking, or vibration, among others. The mechanical motion may beapplied in any number of axes or orientations (e.g., roll, pitch, or yaw) at any frequency. The oscillator 130 can include one or more components to provide the mechanical motion to the battery pack 120. The components may include, for example, one or more actuators to drive mechanical motion to the battery pack 120, support structures, and feedback mechanisms (e.g., control loop) to regulate or stabilize the mechanical motion provided to the battery pack 120, among others. In some embodiments, the components of the oscillator 130 can include at least one speed sensor to carry out the mechanical motion at a specified speed and / or acceleration. The speed sensor can be coupled with the one or more actuators to change, adjust, or otherwise modify the speech or acceleration. The one or more components of the oscillator 130 can be structured to be coupled with the battery pack 120. For example, the actuators may be attached, fastened, or otherwise joined to the battery pack 120. The oscillator 130 can be structured to be communicatively coupled with the controller 105.

[0034] The power supply 135 can convey, deliver, or otherwise provide electrical power to the set of battery cells 140 within the battery pack 120. The power supply 135 can be structured to be electrically coupled with the set of battery cells 140 of the battery pack 120. The power supply 135 can allow for the battery pack 120 to be tested without having the battery cells 140 fully or mostly (e.g., at least 75% of capacity) charged. The power supply 135 may include one or more components to control the delivery of electrical power to the battery cells 140 of the battery pack 120. The components can include, for example, a battery external to the battery cells 140 and a power distributor to control provision to the individual battery cells 140 within the battery pack 120, among others. The power supply 135 can be structured to be communicatively coupled with the controller 105.

[0035] The sensors 115 (sometimes herein referred to as measurement devices or analyzers) can measure, obtain, or otherwise acquire data regarding at least one parameter associated with the battery pack 120, the battery cells 140, or the coolant 180, among others. In some embodiments, at least one sensor 115 can include pre-processing or analysis capabilities on the acquired data. In some embodiments, the sensor 115 may include a thermocouple, and the parameters may include, for example, a temperature of each battery cell 140, a temperature of a housing forming the battery pack 120, a temperature (e.g., of gas) within the battery pack 120, a temperature of at least one of the battery cells 140 (e.g., anexterior skin of the battery cell 140), and a temperature of the coolant 180 within the battery pack 120, among others. In some embodiments, the sensor 115 may include a voltage meter, and the parameter may include a voltage of the battery cells 140. In some embodiments, the sensor 115 may include a current meter, and the parameter may include a current of the battery cells 140. In some embodiments, the sensor 115 may include a power meter, and the parameter may include a power of the battery cells 140. The voltage meter, the current meter, or the power meter may be part of the power supply 135 or a separate component.

[0036] In some embodiments, the sensor 115 may include a refractometer, and the parameters may include, for example, properties of the coolant 180, such as a refractivity of the coolant 180. In some embodiments, the sensor 115 may include at least one probe (or other meter), and the parameters may include, for example, properties of the coolant 180 including electrical resistivity or conductivity measured via the probe. In some embodiments, the sensor 115 may include a gas detector, and the parameters may include presence, absence, or amount (e.g., concentration) of certain gases, such as hydrogen, carbon monoxide, carbon dioxide, hydrocarbon, and volatile organic compounds, among others. The gases may include those formed by the reaction between the coolant 180 and the battery cells 140 during the testing. In some embodiments, the sensor 115 may include a pressure sensor to measure, receive, identify, or otherwise determine a pressure of the gases within the battery pack 120. In some embodiments, the sensor 115 may include a humidity sensor (e.g., hygrometer) and parameter may include, for example, water content or concentration (or humidity) within the interior volume of the battery pack 120. In some embodiments, the sensor 115 may include a spectrometer (e.g., Fourier transform infrared spectroscopy (FTIR)), and the parameter may include species of gases or liquid phases within the battery pack 120.

[0037] The sensors 115 may be structured to be coupled with the battery pack 120 or the battery cells 140, among others, within the testing environment 110. In some embodiments, at least one sensor 115 may be situated, arranged, or otherwise disposed partially within the battery pack 120. The sensor 115 may be structured to be coupled with the battery cells 140 of the battery pack 120. In some embodiments, at least one sensor 115 may be situated, arranged, or otherwise disposed outside the battery pack 120. The sensor 115 can be structured to be coupled with the interior volume of the battery pack 120. Forexample, the sensor 115 can be coupled via one or more pipes to intake the gas from within the battery pack 120. The gases may be taken into a sampling loop that is recirculated at least in part back into the battery pack 120 so that the volume within the battery pack 120 remains closed and isolated from the exterior. In some embodiments, the pipes can be configured or equipped with processing equipment (e.g., a separator, a filter, or demister) to separate liquid and moisture (e.g., water in liquid form separated from water in vaporous form) from the gas or liquids within the interior volume of the battery pack 120. Each sensor 115 can be structured to be communicatively coupled with the controller 105.|0038] The controller 105 (sometimes herein referred to as a computing device or a computing system) can include at least one computing device or server comprising one or more processors 150 coupled with the memory 155 and software, and capable of performing the various processes and tasks described herein. For example, the controller 105 can perform the processes and tasks described herein in conjunction with one or more components in the testing environment 110, such as the sensors 115, the coolant filler 125, the oscillator 130, or the power supply 135, among others. The processors 150 may include a microprocessor, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), etc., or combinations thereof. The memory 155 include, for example, electronic, optical, magnetic, or any other storage or transmission device capable of providing a processor, ASIC, FPGA, etc. with program instructions. The memory may include a memory chip, Electrically Erasable Programmable Read-Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM), flash memory, or any other suitable memory from which the processor of the controller 105. The instructions may include code from any suitable programming language. The memory may include various modules that include instructions which are configured to be implemented by the processors.

[0039] The test administrator 160 executing on the controller 105 can set, configure, or otherwise determine at least one condition to apply during at least one test of the battery pack 120 with the coolant 180. The test may include a simulation of environmental factors to mimic real-world operation conditions that the battery cells 140 or the coolant 180 would experience. The conditions may specify or define the carrying out of the test on the battery pack 120 to evaluate or analyze the performance of the battery pack 120, the battery cells140, or the coolant 180, among others. The conditions may identify, specify, or otherwise include, for example, a type of coolant 180; an amount of coolant 180 to provide; an intake rate of the coolant 180 to provide into the battery pack 120; an outtake rate of the coolant 180 released from the battery pack 120; an amount of voltage, current, or electrical power to the battery cells 140; parameters (e.g., oscillation frequency or force to apply in roll, pitch, or yaw axes, speed, and acceleration) defining the mechanical motion to provide the battery pack 120; a number of tests to provide to the battery pack 120; a time duration and sequence to apply the tests to the battery pack 120, among others. The conditions can be set or configured by an operator of the controller 105. For example, an operator may use one or more input / output (I / O) devices coupled with the controller 105 to set values for the conditions of the test to run on the battery pack 120. Upon entry, the values for the condition can be stored and maintained on the memory 155, and the test administrator 160 can identify the condition for the test from storage on the memory 155.

[0040] The test administrator 160 can carry out, perform, or otherwise execute the test to apply the condition to the battery pack 120 and provide the coolant 180 into the battery pack 120. When the condition is determined to provide the coolant 180 according to specifications, the test administrator 160 can execute the test by causing the coolant filler 125 to provide the coolant 180 according to the specified type, amount, or rate, among others. When the condition is determined to provide the mechanical motion to the battery pack 120, the test administrator 160 can execute the test by causing the oscillator 130 to effectuate or provide the mechanical motion to the battery pack 120 in accordance with the specified parameters. When the determination of the condition to provide the electrical power to the battery cells 140, the test administrator 160 can execute the test by causing the power supply 135 to provide the electrical power through the battery cells 140 of the battery pack 120 in accordance with the specified voltage, current, or power, among others.[00411 In executing the test, the test administrator 160 can produce, output, or otherwise generate one or more control signals to provide to the coolant filler 125, the oscillator 130, or the power supply 135, among others in accordance with the specifications of the condition. For instance, the test administrator 160 can generate a control signal for the coolant filler 125 to provide the amount of coolant 180 into the battery pack 120 at thespecified intake rate. The test administrator 160 can also generate a control signal for the oscillator 130 to apply the mechanical motion to the battery pack 120 according to the specified parameters. The test administrator 160 can generate a control signal for the power supply 135 to deliver the electrical power to the set of battery cells 140 at the specified voltage, current, or power, among others. With the generation of the control signals, the test administrator 160 can transmit, provide, or otherwise send the control signals to the coolant filler 125, the oscillator 130, or the power supply 135, among others. The control signals can be sent in accordance with the time duration and sequence as specified by the condition for the test.

[0042] By sending the control signals, the test can be performed to apply the condition to the battery pack 120. Upon receipt of the control signal from the controller 105, the coolant filler 125 can pump the coolant 180 from the coolant reservoir and deliver the coolant 180 into the interior volume of the battery pack 120. The coolant filler 125 can provide the coolant 180 at the specified amount and intake rate of the control signal. Furthermore, with receipt of the control signal, the oscillator 130 can translate the specifications of the control signal to commands to the actuator to provide mechanical motion to the battery pack 120. The oscillator 130 can provide the mechanical motion via the one or more actuators to move the battery pack 120 along the horizontal plane (e.g., x or y axis) or the vertical plane (e.g., z axis), or any combination thereof, at the frequency and force specified by the control signal. In some embodiments, the oscillator 130 can carry out the mechanical motion via the actuators and the speed sensor at the speed or acceleration specified by the control signal. The speed and / or acceleration may be along any one or more planes (e.g., x, y, or z axes) of the battery pack 120. In addition, upon receipt of the control signal, the power supply 135 can translate the control signal to provide the electrical power at the specified voltage, current, or power, among others. In at least partial concurrence with the test, the sensors 115 can obtain or acquire the data associated with the battery pack 120, the battery cells 140, or the coolant 180. The sensors 115 can transmit, provide, or otherwise send the acquired data to the controller 105.10043] The test administrator 160 can apply the conditions through the coolant filler 125, the oscillator 130, or the power supply 135, among others, in accordance with thespecified time duration and sequence of the condition. The test administrator 160 can maintain a timer to keep track of time identifying an elapsed time for the test. The test administrator 160 can compare the timer with the specified time duration. When the timer is less than the specified time duration, the test administrator 160 can determine to continue with the test and continue to receive the data from the sensors 115. Otherwise, when the timer is greater than or equal to the specified time duration, the test administrator 160 can determine to terminate the test. In some embodiments, the test administrator 160 can proceed to apply the next test and repeat the functionality detailed herein with the subsequent testing.

[0044] The data collector 165 executing on the controller 105 can retrieve, identify, or otherwise receive the data regarding the at least one parameter associated with the battery pack 120, the battery cells 140, or the coolant 180 via the sensor 115. The data can be received from sensor 115 in partial concurrence with the running of the test on the battery pack 120. From the data received from the sensors 115, the data collector 165 can determine or identify a value for the at least one parameter. For example, by processing or parsing the data received from the sensors 115, the data collector 165 can identify the temperature of each battery cell 140; the temperature (e.g., of gas) within the battery pack 120; the temperature of the housing forming the battery pack 120; the temperature of the coolant 180 within the battery pack 120; a voltage of the battery cells 140; a current of the battery cells 140; a power of the battery cells 140; a refractivity of the coolant 180; an electrical resistivity or conductivity of the coolant 180; presence, absence, or amount (e.g., concentration) of certain gases (e.g., hydrogen, carbon monoxide, carbon dioxide, hydrocarbon, and volatile organic compounds); a measurement of pressure of gases within the battery pack 120; water content or concentration (or humidity) within the interior volume of the battery pack 120; and identification of the species of gases or liquid phases within the battery pack 120, among others. The data collector 165 can store and maintain the data (or the values of the parameters) on the memory 155 of the controller 105.

[0045] The performance evaluator 170 executing on the controller 105 can identify or determine at least one classification of the coolant 180 for use with the set of battery cells 140 of the battery pack 120, using the data received from the one or more sensors 115. The classification can define, specify, or otherwise identify whether the coolant 180 is accepted(or approved) or rejected for use with the set of battery cells 140 in the battery pack 120. To determine the classification, the performance evaluator 170 may check or compare the data regarding the one or more parameters with one or more criteria (or criterion). The criteria may specify, define, or otherwise identify a threshold value of each corresponding parameter in which the coolant 180 is identified to be accepted or rejected. For instance, the criteria may specify that a temperature of the coolant 180 within the battery pack 120 is to not exceed 75-95°C and a hydrogen concentration of the gases within the housing forming the battery pack 120 is to not exceed 7-33% of a lower explosive level (LEL) for the gas, among others. In some embodiments, the criteria may specify, define, or otherwise identify a threshold rate of change for the value (e.g., rate of accumulation of hydrogen or temperature rise) or a range of acceptable values for a given type of parameter.

[0046] For each parameter of the data, the performance evaluator 170 can compare the value of the parameter with each threshold value of the corresponding parameters identified by the criteria. If the value of the data does not satisfy (e.g., is greater than or equal to) the threshold value for at least one of the parameters, the performance evaluator 170 can determine the classification of the coolant 180 as disapproved, restricted from, or rejected for the use with the set of battery cells 140. If the value of the data satisfies (e.g., is less than) the threshold value for the parameter, the performance evaluator 170 can determine that the data satisfies the criteria. In addition, the performance evaluator 170 can identify or determine that the coolant 180 is approved, permitted, or otherwise accepted for use with the set of battery cells 140. In some embodiments, when the value of the data satisfies the threshold value for one type of parameter, the performance evaluator 170 can continue to compare the values of other types of parameters with the corresponding threshold values of the criteria. When the values from the data satisfy all the threshold values of the parameters specified by the criteria, the performance evaluator 170 can determine the classification of the coolant 180 as accepted for the use with the set of battery cells 140. With the determination of the classification, the performance evaluator 170 can store and maintain the classification on the memory 155, using one or more data structures (e.g., array, table, matrix, tree, heap, or linked list). The performance evaluator 170 can identify the conditions under which the coolant 180 is identified as accepted or rejected for use with the set of battery cells 140 in the battery pack 120.

[0047] In some embodiments, the performance evaluator 170 can identify or determine whether to continue with another test based on the data received from the one or more sensors 115. In some embodiments, a set of tests can be provided to the battery pack 120, and each test can correspond to an evaluation or analysis of at least one of the parameters. To determine whether to continue, the performance evaluator 170 can compare the value of the parameter with each threshold value of the corresponding parameters identified by the criteria. If the value of the data does not satisfy (e.g., greater than or equal to) the threshold value for at least one of the parameters, the performance evaluator 170 can determine to cease or terminate the testing of the battery pack 120. On the other hand, if the value of the data satisfies (e.g., less than) the threshold value for a given parameter, the performance evaluator 170 determine to continue onto the next test for the battery pack 120. The performance evaluator 170 can provide an indication to the test administrator 160 to identify the next condition for testing.

[0048] The output handler 175 executing on the controller 105 can produce, generate, or otherwise provide at least one output for the test based on the classification of the coolant 180. The output may include information identifying the classification of the coolant 180 as accepted or rejected for use with the set of battery cells 140. When the classification identifies the coolant 180 as accepted for use with the set of battery cells 140, the output handler 175 can generate the output to indicate that the coolant 180 as accepted for use with the set of battery cells 140. Otherwise, when the classification identifies the coolant 180 as rejected for use with the set of battery cells 140, the output handler 175 can generate the output to indicate that the coolant 180 as rejected for use with the set of battery cells 140. In some embodiments, the output handler 175 can include information identifying the conditions used for testing in the output. With the generation of the output, the output handler 175 can provide the output for presentation. For instance, the output handler 175 can generate, render, display, and / or otherwise present the classification of the coolant 180 as well as the information on the conditions for the test on a display that is coupled with the controller 105.

[0049] In this manner, the overall system 100 can facilitate the identification of coolants 180 for use with battery cells 140 and power electronics. In addition, based on the data from the sensors 115, the controller 105 can identify or determine conditions underwhich the coolant 180 is suitable or operable with the set of battery cells 140. Compared to other approaches to test the performance of coolants 180, the test managed and provided by the controller 105 to the battery pack 120 can be used to evaluate lower conductivity coolants with increased corrosion protection and greater service life. The selected coolant 180 can be deployed in battery packs for use in various applications (e.g., electric vehicles or battery storage) to achieve reliable performance with greater corrosion protection and longer lifespans.

[0050] Referring now to FIG. 2, depicted is a block diagram of a system or an environment 200 for simulating various conditions on battery packs. The environment 200 may include one or more components of the system 100 as detailed herein. The environment 200 can include at least one exclusion zone 205 to isolate components therein from the exterior. The environment 200 can include at least one simulated battery pack 210 within the exclusion zone 205. The simulated battery pack 210 can be designed to simulate the environment of at least one battery cell 215 in several ways.

[0051] The simulated battery pack 210 may be a clean, enclosed environment. The simulated battery pack 210 is completely enclosed from the ambient atmosphere. The simulated battery pack 210 may be designed to contain and seal various fluids (e.g., coolant) and gases (e.g., gases formed from coolant interaction with battery cells). The simulated battery pack 210 may be constructed using a non-electrically conducting material, such as high-density polyethylene (HDPE) material. The material can be robust against various fluids including mixtures of glycol and water. Glycol-water coolants may not leach materials from the HDPE material during testing. If ions leach into the test fluid from the simulated battery pack 210, the electrical conductivity of the coolant may be impacted. Electrical conductivity of the liquid coolant in this test can govern temperature rise due to resistive heating and hydrogen generation due to electrolysis.

[0052] Fluids (e.g., coolant fluid) may be added to the simulated battery pack 210 via a coolant filler 225. Along with liquids, the simulated battery pack 210 may be designed to contain gases but may vent (using pressure relief valve or similar), if the pressure inside of the simulated battery pack 210 exceeds 0.3 psig (pounds per square inch gauge), resulting in a failure of the test. Gases may be generated during testing or during battery thermalrunaway. By containing the gases within the simulated battery pack 210, any gases evolved during testing may be measured. This venting strategy may aid with the integrity and overall design and structure of the simulated battery pack 210. The battery packs may be configured to function as pressure vessels, designed to withstand moderate pressures (e.g., 10-20 psig).

[0053] The simulated battery pack 210 can hold a variety of battery cells 215. Battery cells 215 may be held in place (e.g., via clamp) on a cell mounting device 220 to prevent them from moving during vibration or motion of the test apparatus or floating in the test coolant fluid during testing. The battery cell 215 (e.g., prismatic, cylindrical, pouch, or coin) of any chemistry may be evaluated in this simulated battery pack 210. The directionality of the battery cell 215 (e.g., with respect to an orientation of the cathode or anode ends) may be configured or set within the simulated battery pack 210. For instance, the battery cells 215 may be arranged with the anode end toward the top of the simulated battery pack 210 and the cathode end towards the bottom of the simulated battery pack 210, and vice-versa. The battery cells 215 may be oriented about a x, y, or z axis defined through the sides of the simulated battery pack 210 at any range of angles (e.g., 0 to 360 degrees). This simulated battery pack 210 may be used to evaluate the relationship between thermal runaway behavior of battery cell 215 or battery pack 210 and aspects such as factor, type, and chemistry, among others.

[0054] The environment 200 may include at least one power supply 230 (e.g., 1000V, 10 amp) may be deployed to recreate various pack voltages without the reliance for a fully charged battery cell 215. The power supply 230 may be electrically coupled with the battery cell 215 via one or more power supply lines 240. A 1000V power supply 230 may allow the battery cell 215 to be operated at full pack voltages without the reliance for a large amount of stored energy on the battery cell 215. Use of a power supply 230, instead of a full battery pack, may improve the reliability of the simulated battery pack 210. Tests run in this simulated battery pack 210 may be destructive to battery cells 215. Running the test with power supply 230 instead of a full battery pack may allow consumption of less battery cells instead of many (e.g., 1 instead of 500-1000). This may allow for scaling up to the test to any number of battery cells, for a variety of application such as use in an electric vehicle.The power supply 230 may be coupled with a power distribution box 235 to distribute or provide power to the set of battery cells 215 within the simulated battery pack 210.(0055] Various components in the environment 200 may be controlled by a control device. The control device may be used in conjunction to operate sensors, analyzers, and other test controls. For example, the control device may operate remote coolant addition devices and automated test shutoff routines, among others. The environment 200 may also include a linear oscillation device capable of producing linear oscillations of up to 60 cycles per minute to provide a dynamic element to the test. A large shaker table may be used in the apparatus to deliver this capability. Tests with the specific apparatus have shown that an oscillation rate of 20 cycles per minute is sufficient to simulate fluid motion during a vehicle drive cycle.

[0056] The simulated battery pack 210 may use an electrically insulating material (e.g., HDPE or polycarbonate) and may contain a variety of ports (e.g., the ports 250 and 255) for instrumentation and sampling. The ports 250 and 255 can be structured to separate liquids and moisture from the liquids within the interior of the simulated battery pack 210. This can enable accurate and reliable measurements of concentration of hydrogen (Eb) versus other gases within the interior of the battery pack 210. The simulated battery pack 210 and battery cells 215 may be instrumented with several measurement devices, such as a refractometer 245 and a gas analyzer. An array of temperature measurement devices may be used (e.g., thermocouples) to measure temperature of battery cells 215, temperature of the air and gases in the simulated battery pack 210, and the temperature of any liquids that are added to the simulated battery pack 210, among others. In addition, the power distribution box 235 may be equipped with a shunt which is used to measure electrical current and voltage of the battery cell 215 or circuit.

[0057] A refractometer 245 may measure properties of the coolant fluid in the simulated battery pack 210 during testing. The refractometer 245 can be fluidly coupled with the simulated battery pack 210 to ensure circulation of the coolant fluid through the refractometer 245 itself to provide accurate measurements. An electrical conductivity sensor can be used to measure electrical conductivity of the fluid in the simulated battery pack 210 during testing. Initially, the electrical conductivity of the coolant may be set by the substanceof the coolant itself plus any additive content within the liquid coolant. The change in electrical conductivity may be brought about as a result of chemical reactions of the coolant additives with the electrified battery system. During testing, electrical conductivity may be associated with physical processes (e.g., electrolysis and reaction of coolant additives with electrical components) that are relevant to battery thermal events. The reactions involving coolant additives may be evaluated by interpreting data from the sensors (including the refractometer 245, gas sensing devices, pressures sensors, and temperature sensors) or analysis of the coolant, or an end-of-test hardware inspection, among others.|0058] A device for hydrogen measurement (e.g., sensor or chromatograph) may be deployed to measure hydrogen gas that may be evolved from electrolysis or cell venting during testing. Similar devices may be used for measurement of carbon monoxide, carbon dioxide, and total hydrocarbons evolved during testing. Such gases may be created from chemical reaction of the coolant at elevated temperature or conductivity, during cell venting, thermal runaway, or combustion of any fluids in the test environment. The gas sample flow rate for gas analysis and measurement of the sensor can be less than 50 mL per min to 150 mL per min, and the sensor can take a measurement once every 30 seconds to 10 minutes. A humidity sensor may be deployed to measure water content in the atmosphere inside of the simulated battery pack 210. A pressure sensor may be arranged to measure pressure of gases within the simulated battery pack 120, in order to detect potential issues with gas sealing (e.g., faults or breaks) with the simulated battery pack 120 during simulation and testing. Other measurement devices (e.g., spectrograph for Fourier transform infrared (FTIR) spectroscopy) may be deployed to measure various species in gas or liquid phases in the simulated battery pack 210. The gas measurement devices may be contained in a sampling loop that is recirculated to the simulated battery pack 210 so that the overall exclusion zone 205 remains closed.

[0059] The simulated battery pack 210 may have other features, such as a pressure relief valve, material electrical insulating properties, and use of a power supply, among others. The battery cell 215 may be placed in a thermal containment chamber capable of containing fires or explosions related to battery thermal runaway. An electrically insulating material (e.g., silicone or rubber) may be placed between the battery cell 215 and the thermal 1containment chamber to prevent electrical shock. An electrically insulating material can also be placed around the simulated battery pack 210 to protect the technician that works on the apparatus from electrical shock.

[0060] In addition, the sensors (e.g., gas sensors and thermometers) can be used to determine when to continue or terminate a test in the simulated battery pack 210. For example, the test can be stopped if the test environment presents a termination condition, such as when hydrogen gas concentration of the air within the simulated battery pack 210 reaches 7-33% of lower-explosion limit (LEL), the temperature of an exterior skin of the battery cells 215 exceeds 75-90°C, or a flame is detected within the simulated battery pack 210. Furthermore, the test can be also stopped when there is detection of a fault with any one or more of the sensors.

[0061] Referring now to FIG. 3, depicted a block diagram of an apparatus 300 for applying oscillations to a battery module to test coolant and battery performance. The apparatus 300 may include at least one controller 305, at least one simulated battery pack 310, and at least one oscillator 315. The controller 305 can be coupled with various components and the simulated battery pack 310 to facilitate the running of a test. The simulated battery pack 310 may be a closed box containing any number of battery cells 320A-N (hereinafter generally referred to as battery cells 320). The simulated battery pack 310 can contain fluids and gases.

[0062] The simulated battery pack 310 can contain one or more ports 340A-N (hereinafter generally referred to as ports 340) for addition and / or evacuation of fluid from the simulated battery pack 310. The ports 340 can also be used to return the testing environment to an initial condition and to withdraw a portion of the coolant for sampling and analysis. Fluids may be introduced via the ports 340 to the simulated battery pack 310 for testing. In some embodiments, the ports 340 can be coupled with to separate types of liquids or gases (e.g., water from moisture). The plumbing may include one or more pipes (e.g., conduits or channels) and processing equipment (e.g., dryers, membranes, or filters), among others. The separation can serve to accurately measure various measures (e.g., amount, concentration, or pressure) of the gases within the simulated battery pack 310. In some embodiments, the plumbing coupled with the ports 340 can be structured to be coupled withat least one pump (e.g., circulation pump) to channel or remove at least a portion of the liquid or gases from the interior of the simulated battery pack 310 for measurement. For instance, the pump can pull a predefined vacuum (e.g., a 2.0-bar vacuum) on the pipe carrying sample gas from the simulated battery pack. The pressurized sample gas can be passed through a pressure reducing valve. The valve can pass the gas to a pressure reducer or a bypass to recycle the gas back into the simulated battery pack 310. The sample gas that passes through the pressure reducing valve can flow into a water separator, and then into a gas chromatograph mass spectrometer to perform analysis of the gases within the simulated battery pack 310.|0063| The controller 305 can acquire data (e.g., resistive heating and electrolysis) via an array of sensors 335A-N (hereinafter generally referred to as sensors 335) to determine whether a fluid is suitable for use in a battery system. The sensors 335 can measure various data, such as a coolant level 330 of the fluid within the simulated battery pack 310, a measurement of temperature (T) or pressure (P), an identification of gases as well as determination of a concentration of gases within the volume of the simulated battery pack 310 (e.g., hydrogen (H2), water (H2O), and oxygen(C>2)), amount of water, and electrical conductivity (c) of the coolant, among others. The simulated battery pack 310 can be designed to vent in the scenario of increased or excessive pressure inside of the simulated battery pack 310 (e.g., when the pressure exceeds 0.3 psig). The simulated battery pack 310 may be instrumented with a variety of measurement devices. Measurement devices and actions are controlled with the controller 305. The box and experimental environment can use several different features and engineering controls. The simulated battery pack 310 may be placed on the oscillator 315 which is capable of providing linear oscillation (e.g., slosh table or shaker table).

[0064] In this manner, the testing environment along with the controller can carry out various processes (e.g., tests) to simulate real -world conditions to evaluate and assess the performance of coolants under various operational scenario. This comprehensive testing can be used to assess whether the battery pack and coolant can withstand different environmental conditions. From monitoring the parameters using sensors, various data, such as temperature, composition, concentration, pressure, and / or electrical conductivity, among others, about thebattery pack may be obtained. During the execution of the testing, the data can be used to automatically detect potential adverse events (e.g., thermal runaway) and stop tests before damage to the battery cell or pack. These data may be used to pinpoint any issues and make changes to the configuration and design of the battery cell and battery pack as well as selection of coolants for the battery system.

[0065] For example, the controller and the testing environment may be used to assess battery pack design and coolant selection for a battery storage system or an electrical vehicle (EV). The testing environment can be used to test different coolants and battery pack configurations to simulate real-world conditions (e.g., a driving environment for EVs), including charging, discharging, and / or mechanical vibrations, among others. The controller may manage the running of the test on the battery pack by applying electrical power, providing coolant, simulating mechanical vibrations, and introducing other stresses that the battery pack may face in such conditions. In conjunction, an array of sensors can continuously monitor parameters such as temperature, hydrogen concentration, and electrical conductivity, among others, from the battery pack.

[0066] Based on the collected parameters or information, the controller can evaluate the performance of the coolant to classify whether the coolant is to be suitable or unsuitable for use with the battery pack in accordance with criteria. The criteria may specify a range of value for each corresponding parameter under which the coolant is determined to be suitable or unsuitable. If the coolant is classified as unsuitable, the coolant may be excluded from use with the battery pack. On the other hand, if the coolant is classified as suitable by the controller, the coolant may be selected for use with the battery pack. With the selected coolant, the battery pack may be deployed for use with the coolant (e.g., incorporated or added as part of the battery storage system or electric vehicle). The selected coolant may be less susceptible or more able to prevent resistive heating and hydrogen generation preceding or in partial concurrence with onset thermal runaway event. Overall, the comprehensive testing approach can provide a robust framework for evaluating the performance of coolants and battery packs under various environmental conditions.

[0067] Referring now to FIGs. 4A-C depicted are flow diagrams of a process 400 of simulating various conditions on battery packs. The process 400 may be performed orimplemented using any of the components described herein, such as those detailed in conjunction with FIGs. 1-3. Starting with FIG. 4A, under the process 400, a test apparatus may be prepared by cleaning, drying, connecting wiring, and starting emissions equipment (402). A simulated battery pack may be assembled (e.g., by placing battery cells within a volume of the simulated battery pack) (404). A controller connected with the simulated battery pack may start data collection (406). The controller may identify a coolant sample (408).

[0068] The controller may set a fluid level to high or low (410). When the fluid level is set to be low, the controller may cause a coolant filler to add a pre-conditioned coolant into the battery pack to the low fluid level (e.g., 1-5 gallons) (412). Otherwise, when the fluid level is set to be high, the controller may cause the coolant filler to add the pre-conditioned coolant to the high fluid level (e.g., at 5-20 gallons) (414). The controller may also set a power level to low or high (416). When the power level is set to be high, the controller may cause a power supply to provide voltage at a high level (e.g., at 300-500V) (418). Otherwise, when the power level is set to be low, the controller may cause the power supply to provide voltage at a low level (e.g., at 50-150V) (420).[0069| Moving onto FIG. 4B, the controller may determine whether to perform a dynamic test (430). When the determination is made to perform the dynamic test, the controller may cause an oscillator to provide mechanical motion to the battery pack (432). Conversely, when the determination is made to not perform the dynamic test, the controller may refrain from causing the oscillator to provide mechanical motion to the battery pack (434). The controller may use one or more sensors to monitor test data (436). The controller may determine whether a hydrogen concentration exceeds a threshold concentration (e.g., 7- 33% of lower-explosion limit (LEL)) (438). If the hydrogen concentration does not exceed the threshold concentration, the controller may determine whether to continue the test (440). The controller may determine whether system temperatures exceed a threshold temperature (e.g., 75-95°C) (442). If the system temperatures do not exceed the threshold temperature, the controller may determine whether to continue the test (444). The controller may determine whether a test time has elapsed a time limit for the test (e.g., 5-60 minutes) (446).If the test time has not yet elapsed the time limit, the controller may determine whether to continue the test (448) and may continue to monitor test data and repeat from step (436).(0070] Continuing onto FIG. 4C, when the hydrogen concentration exceeds the concentration threshold, the controller can determine whether to conclude the test (460). When the system temperatures exceed the threshold temperature, the controller can determine whether to conclude the test (462). When the test time has exceeded the time limit, the controller can determine whether to conclude the test (464). The controller may determine whether the rate of hydrogen accumulation or the temperature rise exceeds limits for a battery system (466). If the rate of hydrogen accumulation or the temperature rise exceeds acceptable limits, the controller may determine to reject the coolant for use with the battery cells (468). In contrast, if the rate of hydrogen accumulation and the temperature rise do not exceed acceptable limits, the controller may determine to accept the coolant for use with the battery cells (470).(0071 ] Referring now to FIG. 5, depicted is a flow diagram of a method 500 of performing tests to simulate environmental conditions on battery packs. The method 500 may be performed or implemented using any of the components described herein, such as those detailed in conjunction with FIGs. 1-3. In brief overview of the method 500, a controller may determine test conditions (505). The controller may execute the test according to the conditions (510). The controller may receive data from the test (515). The controller may determine whether the data satisfies one or more criteria (520). If the data satisfies the criteria, the controller may determine a classification to accept use of the coolant (525). Otherwise, if the data does not satisfy the criteria, the controller may determine a classification to reject use of the coolant (530). The controller may provide output based on the classification (535).

[0072] In further detail, a controller (e.g., the controller 105 or 305) may identify or determine test conditions to apply to at least one battery pack (505). The test conditions may identify or define various specifications under which testing of the battery pack is to be carried out. The test conditions may include, for example, a type of coolant; an amount of coolant to provide; an intake rate of the coolant; an outtake rate of the coolant; an amount of voltage, current, or electrical power to the battery cells; parameters defining the mechanicalmotion; a number of tests; a time duration and sequence to apply the tests to the battery pack; a combination thereof and potentially others.

[0073] The controller may perform, carry out, or otherwise execute at least one process (e.g., at least one test) according to the conditions (510). In executing the test, the controller may transmit, provide, or otherwise send one or more control signals. The control signal may be applied to various components in the testing environment to carry out the test conditions. The components may include an oscillator, a coolant filler, or a power supply, among others. In some embodiments, the controller may send a control signal for the coolant filler to provide the amount of coolant into the battery pack at the specified intake rate. In some embodiments, the controller may generate a control signal for the oscillator to apply the mechanical motion to the battery pack according to the specified parameters. In some embodiments, the controller may can generate a control signal for the power supply to deliver the electrical power to the battery cells in the battery pack at the specified voltage, current, or power, among others.

[0074] The controller may retrieve, identify, or otherwise receive data from performance of the at least one process (e.g., the test) (515). While running the test, the controller may obtain, collect, or receive the data regarding the at least one parameter associated with the battery pack from one or more sensors. The data may include, for example, temperature of each battery cell; the temperature of gas within the battery pack; the temperature of the housing forming the battery pack; the temperature of the coolant; a voltage of the battery cells; a current of the battery cells; a power of the battery cells; a refractivity of the coolant; an electrical resistivity or conductivity of the coolant; presence, absence, or amount (e.g., concentration) of certain gases (e.g., hydrogen, carbon monoxide, carbon dioxide, hydrocarbon, and volatile organic compounds); a measurement of pressure of gases within the battery pack; water content or concentration (or humidity) within the battery pack; and identification of the species of gases or liquid phases within the battery pack, among others.

[0075] The controller may identify or determine whether the data satisfies one or more criteria (520). The criteria may specify or define ranges of values for the parameters of the data, under which the coolant is to be determined as acceptable or rejected for use withthe battery pack. For each parameter of the collected data, the controller may compare the value of the parameter with the range of values of the corresponding criteria. When the values of the parameters from the data are within the ranges of values of the corresponding criteria, the controller may determine that the data satisfies the criteria. If the data satisfies the criteria, the controller may identify or determine a classification to accept use of the coolant (525). Based on the classification, the coolant may be incorporated or included for use with the battery pack.

[0076] In contrast, when the value of at least one parameter from the data is outside the range of values of the corresponding criteria, the controller may determine that the data does not satisfies the criteria. Otherwise, if the data does not satisfy the criteria, the controller may identify or determine a classification to reject use of the coolant (530). Based on the classification, the coolant may be excluded from use with the battery pack. The controller may send, transmit, or otherwise provide output based on the classification (535). The output may identify or indicate the classification of the coolant. In some embodiments, the output may identify or include the data regarding the one or more parameters. The controller may provide the output for presentation via a display.

[0077] For the purpose of this disclosure, the term “coupled” means the joining or linking of two members directly or indirectly to one another. Such joining may be stationary or moveable in nature. For example, a propeller shaft of an engine “coupled” to a transmission represents a moveable coupling. Such joining may be achieved with the two members or the two members and any additional intermediate members. For example, circuit A communicably “coupled” to circuit B may signify that the circuit A communicates directly with circuit B (i.e., no intermediary) or communicates indirectly with circuit B (e.g., through one or more intermediaries).

[0078] While various circuits with particular functionality are shown in the figures, it should be understood that the components may include any number of circuits for completing the functions described herein. For example, the activities and functionalities of the circuits of the controller 105 may be combined in multiple circuits or as a single circuit. Additional circuits with additional functionality may also be included. Further, the controller may further control other activity beyond the scope of the present disclosure.

[0079] As mentioned above and in one configuration, the “circuits” may be implemented in machine-readable medium for execution by various types of processors. An identified circuit of executable code may, for instance, comprise one or more physical or logical blocks of computer instructions, which may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified circuit need not be physically located together but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the circuit and achieve the stated purpose for the circuit. Indeed, a circuit of computer readable program code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices. Similarly, operational data may be identified and illustrated herein within circuits and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set or may be distributed over different locations including over different storage devices, and may exist, at least partially, merely as electronic signals on a system or network.

[0080] While the term “processor” is briefly defined above, the term “processor” and “processing circuit” are meant to be broadly interpreted. In this regard and as mentioned above, the “processor” may be implemented as one or more general-purpose processors, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), digital signal processors (DSPs), or other suitable electronic data processing components structured to execute instructions provided by memory. The one or more processors may take the form of a single core processor, multi-core processor (e.g., a dual core processor, triple core processor, quad core processor, etc.), microprocessor, etc. In some embodiments, the one or more processors may be external to the apparatus; for example, the one or more processors may be a remote processor (e.g., a cloud-based processor). Alternatively, or additionally, the one or more processors may be internal and / or local to the apparatus. In this regard, a given circuit or components thereof may be disposed locally (e.g., as part of a local server, a local computing system, etc.) or remotely (e.g., as part of a remote server such as a cloud-based server). To that end, a “circuit” as described herein may include components that are distributed across one or more locations.[00811 Although the diagrams herein may show a specific order and composition of method steps, the order of these steps may differ from what is depicted. For example, two or more steps may be performed concurrently or with partial concurrence. Also, some method steps that are performed as discrete steps may be combined, steps being performed as a combined step may be separated into discrete steps, the sequence of certain processes may be reversed or otherwise varied, and the nature or number of discrete processes may be altered or varied. The order or sequence of any element or apparatus may be varied or substituted according to alternative embodiments. All such modifications are intended to be included within the scope of the present disclosure as defined in the appended claims. Such variations will depend on the machine-readable media and hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure.[0082[ The foregoing description of embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from this disclosure. The embodiments were chosen and described in order to explain the principals of the disclosure and its practical application to enable one skilled in the art to utilize the various embodiments and with various modifications as are suited to the particular use contemplated. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the embodiments without departing from the scope of the present disclosure as expressed in the appended claims.[00831 Accordingly, the present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

WHAT IS CLAIMED IS:

1. A system for performing at least one test to simulate at least one environmental condition on at least one battery pack, the system comprising: a controller having one or more processors coupled with memory, the controller configured to: execute a test comprising applying a condition to a battery pack comprising (i) a plurality of battery cells and (ii) a coolant; receive, from a sensor, data regarding at least one parameter associated with at least one of the battery pack or the coolant; determine, using the data from the sensor, a classification of the coolant for use with the plurality of battery cells; and provide an output regarding the test based on the classification of the coolant.

2. The system of claim 1, wherein the controller is further configured to: determine, based on the condition, an amount of electrical power to be provided through the battery pack; and execute the test by causing a power supply to supply the amount of the electrical power through the battery pack in accordance with the condition.

3. The system of claim 1, wherein the controller is further configured to: determine, based on the condition, an amount of the coolant of a coolant type to provide to the battery pack; and execute the test by causing a coolant filler to provide the amount of the coolant of the coolant type to the battery pack in accordance with the condition.

4. The system of claim 1, wherein the controller is further configured to: determine, based on the condition, a plurality of parameters defining at least one vibration provided by an oscillator to the battery pack; and execute the test by causing the oscillator to provide the at least one vibration to the battery pack in accordance with the plurality of parameters of the condition.

5. The system of claim 1, wherein the controller is further configured to determine whether to execute a second test based on the data regarding the at least one parameter.

6. The system of claim 1, wherein the controller is further configured to determine, responsive to the data regarding the at least one parameter satisfying a criterion, the classification to approve the use of the coolant with the plurality of battery cells.

7. The system of claim 1, wherein the controller is further configured to determine, responsive to the data regarding the at least one parameter not satisfying a criterion, the classification to reject the use of the coolant with the plurality of battery cells.

8. The system of claim 1, wherein the data regarding the at least one parameter comprises at least one of (i) a temperature within the battery pack, (ii) a temperature of at least one battery cell of the plurality of battery cells, (iii) a temperature of gas within the battery pack, (iv) a temperature of the coolant, (v) a refractivity of the coolant, (vi) an electrical conductivity, (vii) a hydrogen concentration, (ix) a humidity within the battery pack, (x) or an amount of gases.

9. A method of performing at least one test to simulate at least one environmental condition on at least one battery pack, the method comprising: executing, by a controller, a test comprising applying a condition to a battery pack comprising (i) a plurality of battery cells and (ii) a coolant; receiving, by the controller and from a sensor, data regarding at least one parameter associated with at least one of the battery pack or the coolant; determining, by the controller and using the data from the sensor, a classification of the coolant for use with the plurality of battery cells; and providing, by the controller, an output regarding the test based on the classification of the coolant.

10. The method of claim 9, further comprising determining, by the controller, based on the condition, an amount of electrical power to be provided through the battery pack; andwherein executing the test further comprises causing a power supply to supply the amount of the electrical power through the battery pack in accordance with the condition.

11. The method of claim 9, further comprising determining, by the controller, based on the condition, an amount of the coolant of a coolant type to provide to the battery pack; and wherein executing the test further comprises causing a coolant filler to provide the amount of the coolant of the coolant type to the battery pack in accordance with the condition.

12. The method of claim 9, further comprising determining, by the controller, based on the condition, a plurality of parameters defining at least one vibration to be provided by an oscillator to the battery pack; and wherein executing the test further comprises causing the oscillator to provide the at least one vibration to the battery pack in accordance with the plurality of parameters of the condition.

13. The method of claim 9, further comprising determining, by the controller and responsive to the data regarding the at least one parameter satisfying a criterion, the classification to approve the use of the coolant with the plurality of battery cells.

14. The method of claim 9, further comprising determining, by the controller and responsive to the data regarding the at least one parameter not satisfying a criterion, the classification to reject the use of the coolant with the plurality of battery cells.

15. A system for analyzing at least one battery pack, the system comprising: one or more processors structured to be coupled with a testing environment having a battery pack and a sensor, the one or more processors configured to: execute a test comprising applying a condition to the battery pack comprising (i) a plurality of battery cells and (ii) a coolant;receive, from the sensor, data regarding at least one parameter associated with at least one of the battery pack or the coolant; determine, using the data from the sensor, a classification of the coolant for use with the plurality of battery cells; and provide an output regarding the test based on the classification of the coolant.

16. The system of claim 15, wherein the one or more processors are further configured to: determine, based on the condition, an amount of electrical power to be provided through the battery pack; and execute the test by causing a power supply of the testing environment to supply the amount of the electrical power through the battery pack in accordance with the condition.

17. The system of claim 15, wherein the one or more processors are further configured to: determine, based on the condition, an amount of the coolant of a coolant type to provide to the battery pack; and execute the test by causing a coolant filler of the testing environment to provide the amount of the coolant of the coolant type to the battery pack in accordance with the condition.

18. The system of claim 15, wherein the one or more processors are further configured to: determine the condition identifying a plurality of parameters defining at least one vibration provided by an oscillator of the testing environment to the battery pack; and execute the test by causing the oscillator to provide the at least one vibration to the battery pack in accordance with the plurality of parameters of the condition.

19. The system of claim 15, wherein the one or more processors are further configured to determine, responsive to the data regarding the at least one parameter satisfying a criterion, the classification to approve the use of the coolant with the plurality of battery cells.

20. The system of claim 15, wherein the one or more processors are further configured to determine, responsive to the data regarding the at least one parameter not satisfying a criterion, the classification to reject the use of the coolant with the plurality of battery cells.

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