Systems and methods for thermal management of electrical energy storage devices

Abstract

Embodiments herein disclose systems and methods for performing thermal management of one or more electrical energy storage devices in a charging and interchange station. Embodiments herein disclose systems and methods for performing thermal management of one or more electrical energy storage devices in a charging and interchange station that maintains the temperature of the electrical energy storage device within the ideal operating temperatures.

Description

“Systems and methods for thermal management of electrical energy storage devices” CROSS-REFERENCE TO RELATED APPLICATIONThis application is based on and derives the benefit of Indian Provisional Application IN202441065106, the contents of which are incorporated herein by reference.TECHNICAL FIELD

[0001] Embodiments disclosed herein relate to thermal management of electrical energy storage devices, and more particularly to systems and methods for performing thermal management of electrical energy storage devices in a charging and interchanging station.BACKGROUND

[0002] Electrical energy storage device interchange has emerged as a promising solution in the electric vehicle sector, offering several compelling benefits, such as, but not limited to, significantly reduced wait times, alleviation of range anxiety, and potentially lower overall vehicle costs. However, achieving a robust and forward-looking system requires substantial ongoing research and technological advancements.

[0003] A key area for improvement lies in electrical energy storage device technology itself. In electrical energy storage device interchange systems, the depleted electrical energy storage device is exchanged for a fully charged one at charging and interchange stations. These stations are equipped to charge electrical energy storage devices at varying currents based on demand. During periods of low demand, electrical energy storage devices are charged at a lower current, whereas higher currents are employed during peak demand times.

[0004] Throughout the charging process, managing heat generated by the electrical energy storage device is critical to maintaining its integrity and ensuring long-term usability. Effective monitoring and dissipation of this heat is essential. Additionally, if an electrical energy storage device arrives at the station with a lower-than-optimal temperature, the electrical energy storage device must be carefully heated to bring it up to the necessary operational temperature range.

[0005] The conventional practice of maintaining the temperature of these electrical energy storage devices at the charging and interchange station is by means of air conditioning or Heating, Ventilation, and Air Conditioning (HVAC) systems through which the electrical energy storage devices are maintained at the optimal temperature.

[0006] However, for larger size or high-capacity electrical energy storage devices, it is not possible for their temperatures to be maintained by conventional HVAC systems, especially where the station handles multiple electrical energy storage devices of various capacities.

[0007] Hence, there is a need in the art for solutions that will overcome the above mentioned drawback(s), among others.OBJECTS

[0008] The principal object of embodiments herein is to disclose systems and methods for thermal management of electrical energy storage devices in a charging and interchange station.

[0009] Another object of embodiments herein is to disclose systems and methods for thermal management of electrical energy storage devices in a charging and interchange station, wherein the temperature of the electrical energy storage device is maintained within the ideal operating temperatures.

[0010] Another object of embodiments herein is to provide a thermal management solution that adapts dynamically to varying charging currents and energy demands at the charging and interchange station.

[0011] Another object of embodiments herein is to enable uniform temperature regulation across electrical energy storage devices of different sizes and capacities which are present within the same station.

[0012] Another object of embodiments herein is to minimize energy consumption associated with thermal management while ensuring efficient heat dissipation and retention.

[0013] Another object of embodiments herein is to reduce the dependency on conventional HVAC or air conditioning systems, especially for high-capacity electrical energy storage devices.

[0014] Another object of embodiments herein is to facilitate safe preheating / precooling of electrical energy storage devices that arrive at suboptimal temperatures before initiating charging.

[0015] Another object of embodiments herein is to allow modular and scalable integration of thermal management solutions within existing charging and interchange infrastructure.

[0016] Another object of embodiments herein is to prolong the service life and performance consistency of electrical energy storage devices by avoiding thermal stress during charging.

[0017] Another object of embodiments herein is to automate the thermal management process using real-time monitoring and control systems.

[0018] Another object of embodiments herein is to enhance the reliability and operational uptime of the charging and interchange station under varying environmental and usage conditions

[0019] Another object of embodiments herein is to provide cost-effective and maintainable thermal management techniques suitable for high-throughput interchange stations.

[0020] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating at least one embodiment and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.SUMMARY

[0021] A system for thermal management of electrical energy storage devices comprises a refrigerant circulation unit configured to heat, cool, and circulate refrigerant within the system. The refrigerant circulation unit operates in either heating or cooling mode based on the temperature of the electrical energy storage devices. The refrigerant circulation unit includes a heat exchanger to facilitate heat transfer between the refrigerant and coolant, a compressor to pressurize the refrigerant, a condenser to release or provide heat, a thermal expansion valve (TEV) to regulate flow and reduce pressure, and a flow reversing valve (FRV) to switch between heating and cooling modes. These components are interconnected through conduits to enable refrigerant flow.

[0022] The system further includes a coolant circulation unit for circulating hot or cold coolant within a dock to regulate the temperature of the electrical energy storage devices present in the dock. The coolant circulation unit comprises a primary degassing and collection tank, a secondary degassing and collection tank, multiple pumps for circulation, and valves forcontrolling coolant flow. A coolant circulation conduit is positioned between the inlet of the primary degassing and collector tank and the outlet of the heat exchanger. This conduit may include an inline coolant filter. Another serviceable coolant filter may be installed between the outlet of the primary tank and the inlet of the heat exchanger. A primary coolant pump is placed between the heat exchanger inlet and the outlet of the secondary degassing tank. This pump facilitates coolant circulation within the system.

[0023] The system is designed to be monitored and controlled by a rack supervising unit (RSU) in the battery charging and interchange station. The RSU manages parameters of a rack containing multiple docks for housing electrical energy storage devices. The system may include a cassette detection system within the dock to identify racks that hold the energy storage devices.

[0024] A plurality of thermal sensors is positioned inside the dock to measure the temperature of the storage devices. These sensors may include RS485-based sensors, analogue thermistors, digital temperature sensors, infrared sensors, and contactless types. The system activates heating when the ambient temperature is below a first threshold, and cooling when it meets or exceeds the first threshold.

[0025] The system also includes a high-pressure sensor at the compressor inlet and a low-pressure sensor at the compressor outlet. Each dock may have its own dock pump for circulating coolant, with an optional bypass conduit to route coolant directly from the primary tank to the dock, bypassing the pump.

[0026] Pressure switches may be positioned on conduits at the inlet of each storage device to regulate pressure, and liquid level sensors can be placed inside the primary and secondary tanks.

[0027] Heat exchange between refrigerant and coolant occurs through the heat exchanger, while coolant transfers heat to or from the storage devices via the dock. The flow reversing valve enables switching between heating and cooling by reversing refrigerant flow.

[0028] A method for selecting the operating mode involves initiating the system via the RSU, reading ambient temperature, and determining if it crosses a preset threshold. If the ambient temperature crosses the preset threshold, the system activates cooling by switching off the FRV. . If the ambient temperature does not cross the preset threshold, the system activates heating by switching it on.

[0029] Another method controls the compressor by detecting the presence of an energy storage device in a rack, reading its ambient temperature, and activating the compressor if the recorded ambient temperature exceeds either a second threshold, or a third threshold.

[0030] To control the dock pump, the system detects an energy storage device, measures its maximum and average temperatures, and activates the pump if the maximum and average temperatures exceed respective thresholds. If the maximum temperature or the average temperature is below a threshold, the pump is deactivated.

[0031] The system further comprises a primary solenoid valve, and a secondary solenoid valve, which can be controlled based on presence of the energy storage device, and dock pump status. If the pump is healthy and active, the system opens the primary valve and closes the secondary valve. If the pump fails or is off, the primary valve is closed and the secondary valve is opened.BRIEF DESCRIPTION OF FIGURES

[0032] Embodiments herein are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the following illustrative drawings. Embodiments herein are illustrated by way of examples in the accompanying drawings, in which:

[0033] FIG. 1 is a system for performing thermal management of electrical energy storage devices in a charging and interchange station, according to embodiments as disclosed herein;

[0034] FIG. 2 is a flow chart depicting a control mechanism for selecting modes, according to embodiments as disclosed herein;

[0035] FIG. 3 illustrates the electrical energy storage device thermal management system in “Heating mode”, according to embodiments as disclosed herein;

[0036] FIG. 4 illustrates the electrical energy storage device thermal management system in “Cooling mode”, according to embodiments as disclosed herein;

[0037] FIG. 5 is an example flow chart depicting the process of controlling the compressor, according to embodiments as disclosed herein;

[0038] FIG. 6 is an example flow chart depicting the process of controlling the dock pump, according to embodiments as disclosed herein; and

[0039] FIG. 7 is a flow chart depicting the process of controlling the solenoid valve, according to embodiments as disclosed herein.DETAILED DESCRIPTION

[0040] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as not to unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0041] For the purposes of interpreting this specification, the definitions (as defined herein) will apply, and whenever appropriate, the terms used in the singular will also include the plural and vice versa. It is to be understood that the terminology used herein is for the purposes of describing particular embodiments only and is not intended to be limiting. The terms “comprising”, “having” and “including” are to be construed as open-ended terms unless otherwise noted.

[0042] The words / phrases "exemplary", “example”, “illustration”, “in an instance”, “and the like”, “and so on”, “etc.”, “etcetera”, “e.g.,”, “i.e.,” are merely used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein using the words / phrases "exemplary", “example”, “illustration”, “in an instance”, “and the like”, “and so on”, “etc.”, “etcetera”, “e.g.,”, “i.e.,” is not necessarily to be construed as preferred or advantageous over other embodiments.

[0043] Embodiments herein may be described and illustrated in terms of blocks which carry out a described function or functions. These blocks, which may be referred to herein as managers, units, modules, hardware components or the like, are physically implemented by analogue and / or digital circuits such as logic gates, integrated circuits, microprocessors, microcontrollers, memory circuits, passive electronic components, active electronic components, optical components, hardwired circuits and the like, and may optionally be driven by a firmware. The circuits may, for example, be embodied in one or more semiconductor chips, or on substrate supports such as printed circuit boards and the like. The circuits constituting a block may be implemented by dedicated hardware, or by a processor (e.g., oneor more programmed microprocessors and associated circuitry), or by a combination of dedicated hardware to perform some functions of the block and a processor to perform other functions of the block. Each block of the embodiments may be physically separated into two or more interacting and discrete blocks without departing from the scope of the disclosure. Likewise, the blocks of the embodiments may be physically combined into more complex blocks without departing from the scope of the disclosure.

[0044] It should be noted that elements in the drawings are illustrated for the purposes of this description and ease of understanding and may not have necessarily been drawn to scale. For example, the flowcharts / sequence diagrams illustrate the method in terms of the steps required for understanding aspects of the embodiments as disclosed herein. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the present embodiments so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Furthermore, in terms of the system, one or more components / modules which comprise the system may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the present embodiments so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0045] The accompanying drawings are used to help easily understand various technical features and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any modifications, equivalents, and substitutes in addition to those which are particularly set out in the accompanying drawings and the corresponding description. Usage of words such as first, second, third etc., to describe components / elements / steps is for the purposes of this description and should not be construed as sequential ordering / placement / occurrence unless specified otherwise.

[0046] The embodiments herein achieve systems and methods for performing thermal management of one or more electrical energy storage devices in a charging and interchange station. Referring now to the drawings, and more particularly to FIGS. 1 through 7, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.

[0047] Embodiments herein disclose intelligent thermal management systems within charging and interchange stations. The intelligent thermal management systems can regulate and maintain electrical energy storage devices at their ideal operating temperatures, thereby enhancing reliability and longevity in the electrical energy storage device-interchange infrastructure.

[0048] The following terms / components / systems and corresponding reference numerals have been referred to herein:100 - system for thermal management of electrical energy storage devices (BTMS)110 - Refrigerant circulation unit112 - Heat exchanger114 - Compressor116 - Condenser118 - Thermal expansion valve120 - Flow reversing valve122 - Refrigerant filter drier124 - High Pressure sensor126 - Low pressure sensor128 - Fan150 - Coolant circulation unit152 - Primary degassing and collector tank154 - Inline coolant filter156 - Secondary degassing and collector tank158 - Serviceable coolant filter160 - Bypass conduit162 - Dock pump164 - Primary solenoid valve166 - Secondary solenoid valve168 - Primary Pump170 - pressure switch172 - liquid level sensorEESD - Electrical energy storage device

[0049] The charging and interchange station is provided with multiple racks having charging and storage compartments or docks for housing the electrical energy storage devices (which can also be referred to herein as a cassette). Each rack includes a Rack Supervising Unit (RSU) that monitors and controls the parameters of the rack. The RSU also monitors and controls the system for thermal management of the electrical energy storage device . The system regulates the temperature of the electrical energy storage devices EESD within the docks to be within the optimal range. A cassette detection system is provided to detect a cassette having one or more electrical energy storage devices (EESD) within the dock and report it to the RSU. Once the cassette is detected within the dock, a plurality of temperature sensors are provided in the dock for measuring the temperature of the electrical energy storage devices and reporting the measured temperature to the RSU. Based on the measured data, the RSU regulates the temperature within the docks to heat or cool the electrical energy storage devices present within the docks. In an embodiment herein, the temperature sensors can be, but not limited to, RS485-based sensors, analogue thermistors, digital temperature sensors, infrared sensors, contactless thermal sensors, and so on.

[0050] FIG. 1 illustrates a schematic diagram of a thermal management system 100 for electrical energy storage devices. The system 100 comprises a refrigerant circulation unit 110, and a coolant circulation unit 150. The refrigerant circulation unit 110 is configured to heat, cool, and circulate the refrigerant within the system. The coolant circulation unit 150 is configured to circulate hot or cold coolant within the dock to cool or heat the electrical energy storage devices EESD (as required).

[0051] The refrigerant circulation unit 110 is provided with a heat exchanger 112, a compressor 114, a condenser 116, a Thermal expansion valve (TEX) 118, and a Flow reversing valve (FRV) 120. Each component of the refrigerant circulation unit 110 is functionally connected through a conduit for enabling the circulation of the refrigerant. The refrigerant circulation unit 110 is configured to operate in heating mode or cooling mode based on the temperature of the electrical energy storage devices (EESD).

[0052] The compressor 114 pressurizes the refrigerant, increasing its temperature and energy content. The compressor 114 is equipped with a high-pressure sensor 124 at its inlet and a low-pressure sensor 126 at its outlet, allowing for precise monitoring and control of the refrigerant pressure throughout the system.

[0053] The condenser 116 is responsible for releasing heat from the refrigerant to the environment. In cooling mode, the condenser 116 cools and condenses the high-pressure, high- temperature refrigerant from the compressor 114. In heating mode, the condenser 116 can serve as a heat source for the refrigerant.

[0054] The thermal expansion valve (TEV) 118 regulates the flow of refrigerant into the heat exchanger 112. The heat exchanger 112 reduces the pressure of the liquid refrigerant, thereby allowing the liquid refrigerant to expand and cool rapidly. This process is crucial for the system's ability to absorb heat from the coolant in cooling mode.

[0055] The flow reversing valve (FRV) 120 allows the system to switch between heating and cooling modes. By reversing the flow of refrigerant, the FRV 120 changes the roles of the heat exchanger 112 and condenser 116, enabling the system to provide either heating or cooling as required.

[0056] The coolant circulation unit 150 includes a primary degassing and collection tank 152, a secondary degassing and collection tank 156, and a plurality of valves and pumps for circulating coolant through the system.

[0057] In the coolant circulation unit 150, the primary degassing and collection tank 152 serves as the main reservoir for the coolant. The primary degassing and collection tank 152 allows for the separation of any gases that may have become entrained in the coolant during circulation. The primary degassing and collection tank 152 is equipped with a liquid level sensor 172 to monitor coolant levels and ensure proper system operation.

[0058] The secondary degassing and collection tank 156 provides an additional stage of gas separation and coolant collection. Like the primary tank, the secondary degassing and collection tank 156 is also equipped with a liquid level sensor 172. This dual -tank configuration enhances the system's ability to maintain a gas-free coolant supply, which is crucial for efficient heat transfer and system performance.

[0059] A primary coolant pump 168 is positioned between the inlet of the heat exchanger 112 and the outlet of the secondary degassing and collector tank 156. The primary coolant pump 168 is responsible for circulating coolant throughout the coolant circulation unit150, ensuring a continuous flow of coolant through the electrical energy storage devices and the heat exchanger.

[0060] For each dock in the system, a dock pump 162 is provided to circulate coolant specifically to that dock. This allows for individualized control of coolant flow to each electrical energy storage device. A bypass conduit 160 is also included, allowing the coolant to circulate from the primary degassing and collector tank 152 to the dock, bypassing the dock pump 162 if necessary.

[0061] To maintain optimal coolant quality, an inline coolant filter 154 is installed in the coolant circulation conduit between the outlet of the heat exchanger 112 and the inlet of the primary degassing and collector tank 152. Additionally, a serviceable coolant filter 158 is positioned between the outlet of the primary degassing and collection tank 152 and the inlet of the heat exchanger 112, allowing for easy maintenance and replacement.

[0062] At each inlet of the electrical energy storage devices, a pressure switch 170 is installed on the coolant conduit. The pressure switch 170 regulate the coolant pressure at the inlet of each electrical energy storage device, ensuring consistent and appropriate coolant flow across all devices in the system.

[0063] The thermal management system 100 operates in two primary modes: a heating mode, and a cooling mode.

[0064] FIG. 2 illustrates a flow chart depicting a control mechanism for selecting modes by the electrical energy storage device thermal management system. The flowchart outlines the decision-making process for activating either the cooling mode or the heating mode based on the ambient temperature of the electrical energy storage device (EESD). The system utilizes a rack supervising unit (RSU) (not shown) to initiate the BTMS 100 and monitor the ambient temperature.

[0065] The RSU initiates the system for thermal management of the Electrical energy storage device (BTMS) 100 by reading the ambient temperature (Ta) from a temperature, pressure, and humidity (TPH) sensor (not shown) over an interface (such as, but not limited to, RS485 communication interface, and so on). The TPH sensor provides accurate temperature readings, enabling the system to make informed decisions about the appropriate thermal management mode.

[0066] The decision-making process involves two main decision points. The first decision point checks if the Ta signal is 'O' or if there is an error in reading. This step ensuresthat the system has valid temperature data before proceeding with mode selection. If an error is detected or the signal is 'O', the system takes appropriate action to maintain safe operation.

[0067] The second decision point evaluates whether the ambient temperature (Ta) is greater than or equal to a pre-determined first temperature threshold, (for example, 1°C, 2°C, 5°C, 7°C, and so on). The first temperature threshold serves as the boundary between activating the cooling mode or the heating mode.

[0068] If the ambient temperature of the electrical energy storage device (EESD) is less than the pre-determined first temperature threshold, then the BTMS 100 can activate the heating mode.

[0069] Based on these decision points, the system determines the appropriate mode of operation. If the ambient temperature (Ta) is greater than or equal to the pre-determined first temperature threshold, the BTMS 100 can activate the cooling mode. In this case, the BTMS 100 sets its mode to 'cooling' and switches 'OFF' the Flow Reversing Valve (FRV) 120. The FRV 120 can direct the flow of refrigerant within the refrigerant circulation unit 110, wherein the state of the FRV 120 (ON / OFF) determines the direction of refrigerant flow.

[0070] Conversely, if the ambient temperature (Ta) is less than the pre-determined first temperature threshold, the BTMS 100 can activate the heating mode. In this scenario, the BTMS 100 sets its mode to 'heating' and switches 'ON' the FRV 120. The activation of the FRV 120 in heating mode allows the system to reverse the flow of refrigerant, enabling the transfer of heat to the electrical energy storage devices EESD.

[0071] FIG. 2 also accounts for situations where the Ta signal might be 'O' or there is an error in reading. In such cases, as a safety measure, the system switches 'OFF' the FRV 120. This precautionary step ensures that the system remains in a safe state when accurate temperature data is unavailable, preventing potential damage to the electrical energy storage devices EESD.

[0072] The control mechanism illustrated in FIG. 2 demonstrates the adaptive nature of the BTMS 100. By continuously monitoring the ambient temperature and adjusting its operation mode accordingly, the system ensures that the electrical energy storage devices EESD are maintained at their optimal operating temperature. This adaptive approach contributes to the enhanced reliability and longevity of the electrical energy storage deviceinterchange infrastructure.

[0073] The flowchart in FIG. 2 represents a simplified version of the control logic implemented in the BTMS 100. In practice, the system may incorporate additional sensors, decision points, and control parameters to fine-tune its operation. For instance, the system could include hysteresis to prevent rapid switching between modes when the ambient temperature fluctuates around the threshold value. Additionally, the system could incorporate predictive algorithms that anticipate temperature changes based on historical data or external factors, allowing for proactive mode switching.

[0074] FIG. 3 illustrates a BTMS in heating mode. In the heating mode, refrigerant present in the refrigerant circulation unit 110 gains heat in the condenser 116 to a predetermined temperature and is sent to the compressor 114 for compression. The predetermined temperature can be based on an initial battery temperature and the amount of heating required. The pressurized heat-gained refrigerant from the compressor 114 flows to the heat exchanger 112, where the pressurized heat-gained refrigerant transfers the heat to the coolant, thereby effectively heating the coolant. The cooled pressurized refrigerant then proceeds to a Thermal expansion valve (TXV) 118, where the refrigerant is relieved of its pressure. The cooler depressurized refrigerant is then sent to the condenser 116 for heating and the cycle repeats.

[0075] In the coolant circulation unit 150, the heated coolant from the heat exchanger 112 is sent to the primary degassing and collection tank 152, where the heated coolant is degassed and collected. The heated coolant is circulated to the cassette having electrical energy storage devices EESD through the dock. The heat from the hot coolant is then transferred to the electrical energy storage device EESD through the cassette. The cooler coolant is then sent to the secondary degassing and collection tank 156 for coolant collection. The collected coolant is sent to the heat exchanger 112 and the cycle repeats.

[0076] FIG. 4 illustrates a BTMS in cooling mode. In the cooling mode, the FRV 120 is activated which reverses the flow of refrigerant and diverts the flow of refrigerant to the heat exchanger 112 from the condenser 116 instead of the compressor 114 (as in the heating mode). The cooler refrigerant from the condenser 116 flows to the heat exchanger 112 through the TXV 118 which depressurizes the cooler refrigerant. The depressurized cooler refrigerant absorbs heat from the coolant, thereby cooling the coolant. The heated refrigerant then flows to the compressor 114 through the FRV 120, where the hot refrigerant is pressurized and sent to the condenser 116 for cooling. The cooler refrigerant is further sent to the heat exchanger 112 and the cycle repeats.

[0077] In the coolant circulation unit 150, the cooler coolant from the heat exchanger 112 is sent to the primary degassing and collection tank 152, where the coolant is degassed and collected. The cooler coolant is circulated to the cassette through the dock. The heat generated in the electrical energy storage device is then transferred to the coolant. The heated coolant is further sent to the secondary degassing and collection tank 156 for coolant collection. The collected coolant is sent to the heat exchanger 112 to transfer the heat from the coolant to the refrigerant and the cycle repeats.

[0078] In an embodiment herein, a refrigerant filter drier 122 is provided to filter out any impurities in the refrigerant.

[0079] In an embodiment herein, a fan 128 is provided to direct atmospheric air toward the condenser for condensing the refrigerant.

[0080] In an embodiment herein, a coolant circulation conduit is provided between an inlet of the primary degassing and collector tank 152 and an outlet of the heat exchanger 112, wherein the coolant circulation conduit is provided with an inline coolant filter 154. In another embodiment herein, a serviceable coolant filter 158 is provided between the outlet of the primary degassing and collection tank 152 and the inlet of the heat exchanger 112.

[0081] FIG. 5 illustrates a flowchart for compressor control operation based on electrical energy storage device (EESD) presence within the dock and temperature of an electrical energy storage device thermal management system. FIG. 5 depicts a control mechanism for selecting operational modes of the system, which plays a vital role in regulating and maintaining electrical energy storage devices at their ideal operating temperatures, thereby enhancing reliability and longevity in the electrical energy storage device-interchange infrastructure.

[0082] The process begins with the RSU determining the presence of EESDs in the docks in the charging and interchange station. This enables the RSU to determine the overall system status and initiate appropriate thermal management actions. The RSU is configured to monitor and control the parameters of a rack having a plurality of docks, ensuring efficient operation of the entire system.

[0083] On determining the presence of the EESDs in the docks, the system proceeds to a series of decision points that guide the subsequent actions. The first decision point evaluates whether the EESD presence for all docks is greater than zero. This check ensures that thesystem only activates when there is battery pack present in the dock, optimizing energy usage and system efficiency.

[0084] The next decision point assesses if ambient temperature (Ta) of a EESD is greater than a pre-determined second temperature threshold (for example, 1°C, 2°C, 5°C, 7°C, and so on). The pre-determined second temperature threshold can be used to determine whether cooling or heating mode should be activated. If any EESD temperature exceeds the predetermined second temperature threshold, the system switches on the FRV 120, initiating the cooling mode. The FRV 120 plays a crucial role in reversing the flow of refrigerant, diverting it to the heat exchanger 112 from the condenser 116, instead of the compressor 114.

[0085] Another critical decision point evaluates if all EESD temperatures are below a pre-determined third temperature threshold (for example, 8°C, 10°C, 12°C, and so on). If this condition is met, the system switches off the compressor (COMP) 114. This prevents unnecessary cooling when the battery packs are already at a sufficiently low temperature, contributing to energy conservation and system longevity.

[0086] If none of the above conditions are met, the system defaults to switching on the FRV 120. This ensures that the system maintains an appropriate thermal environment for the battery packs under various conditions not covered by the specific temperature thresholds.

[0087] FIG. 6 illustrates a flowchart for dock pump control based on battery pack (EESD) presence and temperature in the electrical energy storage device thermal management system. FIG. 6 depicts a control mechanism for selecting modes of operation for the dock pump, which can regulate the temperature of the electrical energy storage devices within the charging and interchange station.

[0088] The process begins with the RSU determining the presence of EESDs in the docks in the charging and interchange station. This enables the RSU to determine as to whether an electrical energy storage device is present in the dock, and requires thermal management. The RSU utilizes sensors or detection mechanisms to identify the presence of a battery pack within the dock.

[0089] Following the EESD presence detection, the system evaluates two critical decision points. The first decision point assesses whether the EESD present signal is 'O' or if there is an error in reading. This check ensures the system can respond appropriately to situations where a battery pack is not detected or when there are issues with the detection mechanism.

[0090] The second decision point evaluates the temperature conditions of the battery pack. Specifically, it checks if the maximum battery temperature (Btmax) is greater than or equal to a fourth temperature threshold (for example, 25°C, 27°C, 28°C, 30°C, 32°C, and so on) and if the average battery pack temperature (Tavg) is greater than or equal to average temperature threshold (for example, 21°C, 23°C, 25°C, 27°C, and so on). These temperature thresholds are crucial for determining whether cooling is required to maintain the optimal operating temperature of the electrical energy storage devices.

[0091] Based on these decision points, the system determines the appropriate action for the dock pump. If the EESD present signal is 'O' or there is an error in reading, the system switches the dock pump 'OFF'. This prevents unnecessary operation of the pump when no battery pack is present or when there are detection issues.

[0092] If the temperature conditions meet or exceed the specified thresholds (for example, Btmax > 28°C and EESDTavg > 25°C), the system switches the dock pump 'ON'. This action initiates the circulation of coolant to the battery pack, facilitating heat transfer and maintaining the optimal temperature range for the electrical energy storage devices.

[0093] In cases where neither of the above conditions is met, the system switches the dock pump 'OFF'. This ensures energy efficiency by operating the pump only when necessary for thermal management.

[0094] FIG. 6 also indicates that additional input in the form of EESD live data for temperature readings is utilized. This real-time temperature data allows for continuous monitoring and adjustment of the thermal management system, ensuring precise control over the battery pack temperatures.

[0095] The dock pump control process illustrated in FIG. 6 demonstrates the intelligent and adaptive nature of the thermal management system. By continuously monitoring battery pack presence and temperature, and adjusting the dock pump operation accordingly, the system maintains optimal operating conditions for the electrical energy storage devices. This approach enhances the reliability, efficiency, and longevity of the battery packs within the charging and interchange station infrastructure.

[0096] FIG. 7 illustrates a flowchart for solenoid valve control based on battery pack (EESD) presence and pump health in the electrical energy storage device thermal management system. FIG. 7 depicts the decision-making process for controlling solenoid valves SI 164 and S2 166, based on the presence of a battery pack in the dock and the health status of the pump.This control mechanism is an integral part of the system for thermal management of the Electrical energy storage device (BTMS) 100, ensuring efficient and safe operation of the cooling system.

[0097] The process begins with the RSU determining the presence of EESDs in the docks in the charging and interchange station. This enables the RSU to determine as to whether a battery pack is present and ready for thermal management. The RSU utilizes sensors or detection mechanisms to accurately detect the presence or absence of a battery pack in the dock. This information is then used as a primary input for the subsequent decision-making process.

[0098] Following the EESD presence detection, the system evaluates two critical decision points. The first decision point assesses whether a EESD is present in the dock. This determination is based on the reading obtained by the RSU in the previous step. The second decision point evaluates the health status of the pump. The pump health assessment is likely performed through various parameters such as, but not limited to, operational status, pressure readings, or other relevant metrics that indicate the pump's ability to circulate coolant effectively.

[0099] Based on these decision points, the system determines the appropriate configuration for the primary solenoid valves (SV SI) 164 and secondary solenoid valves (SV S2) 166. The solenoid valves 164, 166 direct the flow of coolant within the thermal management system. The solenoid valves 164, 166 are controlled to ensure optimal cooling or heating of the battery pack when present, and to prevent unnecessary circulation when no battery pack is installed or when the pump is not functioning correctly.

[0100] FIG. 7 outlines three possible outcomes based on the decision points. In the first scenario, if no EESD is present in the dock, the system activates the secondary solenoid valve 166 (SV S2 'ON') and deactivates the primary solenoid valve 164 (SV SI 'OFF'). This configuration redirects the coolant flow to bypass the empty dock, preventing unnecessary circulation and conserving energy.

[0101] In the second scenario, if a EESD is present in the dock but the pump is not healthy, the system maintains the same valve configuration as in the first scenario (SV S2 'ON' and SV SI 'OFF'). This setting may be a safety measure to prevent potential issues that could arise from circulating coolant with a malfunctioning pump, even when a battery pack is present.

[0102] The third scenario represents the ideal operating condition, wherein a EESD is present in the dock, and the pump is healthy. In this case, the system activates the primary solenoid valve 164 (SV SI 'ON') and deactivates the secondary solenoid valve 166 S2 (SV S2 'OFF'). This configuration allows the coolant to circulate through the dock, enabling effective thermal management of the installed battery pack.

[0103] The solenoid valve control mechanism illustrated in FIG. 7 demonstrates the system's ability to adapt to different operational conditions. By considering both the presence of a battery pack and the health of the pump, the system can optimize coolant flow, enhance energy efficiency, and maintain safe operating conditions for the electrical energy storage devices.

[0104] This control mechanism can be further enhanced by incorporating additional sensors or monitoring systems to provide more detailed information about the battery pack's thermal state or the overall system conditions. For example, temperature sensors within the dock could provide input to fine-tune the valve control based on the actual thermal needs of the battery pack.

[0105] Alternative embodiments of this control system could include variableposition valves instead of binary on / off solenoid valves, allowing for more precise control of coolant flow. Additionally, the system could be expanded to handle multiple docks simultaneously, with individual valve control for each dock based on its specific battery pack presence and thermal requirements.

[0106] The solenoid valve control process illustrated in FIG. 7 can ensure that the cooling or heating of electrical energy storage devices is performed efficiently and safely under various operational conditions. This adaptive control mechanism contributes significantly to the longevity and reliability of the battery packs within the charging and interchange infrastructure.

[0107] In an embodiment herein, the difference in coolant temperature at the inlet of the electrical energy storage device and the outlet of the electrical energy storage device should not be greater than the pre-determined first temperature threshold. If the temperature difference is greater than the pre-determined first temperature threshold, the RSU generates an error message indicating unusual heating of the electrical energy storage device, restricts the electrical energy storage device from further charging process, provides an alert to an authorized user, and blocks the electrical energy storage device from further dispensing.

[0108] The embodiments described herein have several technical advantages including, but not limited to, the realization of a systems and methods for thermal management of electrical energy storage devices,• that enable efficient regulation of device temperature during charging, discharging, and idle states;• that support both heating and cooling functionalities based on ambient and operational conditions;• that allow for responsive thermal control through integration with supervisory control units;• that facilitate enhanced safety by maintaining thermal conditions within safe operating limits;• that improve energy storage performance and longevity through optimized thermal environments;• that adapt thermal operation modes dynamically based on real-time sensor data;• that ensure uniform thermal distribution across multiple energy storage devices within a rack or dock;• that provide modularity and scalability for use across varied energy storage configurations and station sizes;• that reduce thermal management system downtime through predictive control and redundancy; and• that enable integration with station-level diagnostics for improved monitoring and maintenance.

[0109] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments and examples, those skilled in the art will recognize that the embodiments and examples disclosed herein can be practiced with modification within the scope of the embodiments as described herein.

Claims

STATEMENT OF CLAIMSWe claim:

1. A system for thermal management of electrical energy storage devices in a battery charging and interchange station, comprising: a refrigerant circulation unit (110) configured to heat, cool, and circulate a refrigerant within the system, wherein the refrigerant circulation unit (110) includes: a heat exchanger (112) configured to facilitate heat transfer between the refrigerant and a coolant; a compressor (114) configured to pressurize the refrigerant; a condenser (116) configured to release heat from or provide heat to the refrigerant; a thermal expansion valve (TEV) (118) configured to regulate the flow of refrigerant and reduce its pressure; and a flow reversing valve (FRV) (120) configured to switch between heating and cooling modes by reversing the flow of refrigerant, wherein the components of the refrigerant circulation unit (110) are functionally connected through conduits for enabling the circulation of the refrigerant; and a coolant circulation unit (150) configured to circulate the hot or cold coolant within a dock to one of cool or heat the electrical energy storage devices as required, wherein the coolant circulation unit (150) includes: a primary degassing and collection tank (152); a secondary degassing and collection tank (156); a plurality of pumps for circulating coolant through the coolant circulation unit (150); and a plurality of valves for controlling coolant flow through the coolant circulation unit (150), wherein the refrigerant circulation unit (110) is configured to operate in one of one of a heating mode or cooling mode based on the temperature of the electrical energy storage devices.

2. The system as claimed in claim 1, wherein a rack supervising unit (RSU) is configured to manage parameters of a rack having a plurality of docks configured to house the electrical energy storage devices (EESD) in the battery charging and interchange station.

3. The system as claimed in claim 1, wherein the system includes a cassette detection system positioned within the dock and configured to detect presence of a cassette having a plurality of electrical energy storage devices in a dock in the battery charging and interchange station.

4. The system as claimed in claim 1, wherein the system includes a plurality of temperature sensors positioned within the dock for measuring temperature of the electrical energy storage devices (EESD).

5. The system as claimed in claim 1, wherein the refrigerant circulation unit (110) is configured to operate in a heating mode or a cooling mode based on the temperature of the electrical energy storage devices, wherein the heating mode is activated when an ambient temperature of the electrical energy storage devices is less than a pre-determined first temperature threshold, and the cooling mode is activated when the ambient temperature of the electrical energy storage devices is greater than or equal to the pre-determined first temperature threshold.

6. The system as claimed in claim 1, wherein the system includes a coolant circulation conduit positioned between an inlet of the primary degassing and collector tank (152) and an outlet of the heat exchanger (112), wherein the coolant circulation conduit includes an inline coolant filter (154).

7. The system as claimed in claim 1, wherein the system includes a serviceable coolant filter (158) positioned between an outlet of the primary degassing and collection tank (152) and an inlet of the heat exchanger (112).

8. The system as claimed in claim 1, wherein the system includes a high-pressure sensor (124) positioned at an inlet of the compressor (114), and a low-pressure sensor (126) positioned at an outlet of the compressor (114).

9. The system as claimed in claim 1, wherein the system includes a dock pump (162) for each of the docks in the battery charging and interchange station for circulation of coolant to the particular dock.

10. The system as claimed in claim 9, wherein the system includes a bypass conduit (160) configured to circulate the coolant to the dock from the primary degassing and collector tank (152) bypassing the dock pump (162).

11. The system as claimed in claim 1, wherein the system includes a primary coolant pump (168) positioned between an inlet of the heat exchanger (112) and an outlet of the secondary degassing and collector tank (156), wherein the primary coolant pump (168) is configured to circulate the coolant within the coolant circulation unit (150).

12. The system as claimed in claim 1, wherein the system includes a pressure switch (170) positioned on a conduit at each inlet of the electrical energy storage device, wherein the pressure switch (170) is configured to regulate coolant pressure at the inlet of each electrical energy storage device.

13. The system as claimed in claim 1, wherein the system includes at least one liquid level sensor (172) positioned in the primary degassing and collection tank (152) and the secondary degassing and collection tank (156).

14. The system as claimed in claim 1, wherein the refrigerant circulation unit (110) is configured to transfer heat between the refrigerant and the coolant via the heat exchanger (H2).

15. The system as claimed in claim 1, wherein the coolant circulation unit (150) is configured to transfer heat between the coolant and the electrical energy storage devices (EESD) via the dock.

16. The system as claimed in claim 1, wherein the flow reversing valve (FRV) (120) is configured to reverse the flow of refrigerant within the refrigerant circulation unit (110) to switch between heating mode and cooling mode.

17. A method for selecting an operating mode for thermal management of electrical energy storage devices in a battery charging and interchange station, the method comprising: reading, by a system for thermal management of electrical energy storage devices (BTMS), an ambient temperature (Ta) from a temperature sensor; determining, by the BTMS, if the ambient temperature (Ta) is greater than or equal to a predetermined first temperature threshold;activating, by the BTMS, a cooling mode by switching off a Flow Reversing Valve (FRV) (120) if the ambient temperature (Ta) is greater than or equal to the pre-determined first temperature threshold; and activating, by the BTMS, a heating mode by switching on the Flow Reversing Valve (FRV) (120) if the ambient temperature (Ta) is less than the pre-determined first temperature threshold.

18. A method for controlling a compressor (114) in a system (100) for thermal management of electrical energy storage devices in a battery charging and interchange station, the method comprising: determining, by a system for thermal management of electrical energy storage devices (BTMS), if at least one electrical energy storage device is present in a dock in the battery charging and interchange station; measuring, by the BTMS, an ambient temperature (Ta) of the at least one electrical energy storage device in the battery charging and interchange station; activating, by the BTMS, the compressor (114) if the ambient temperature (Ta) is greater than a pre-determined second temperature threshold; and activating, by the BTMS, the compressor (114) if the ambient temperature (Ta) is not less than a pre-determined third temperature threshold.

19. A method for controlling a dock pump (162) in a system (100) for thermal management of electrical energy storage devices in a battery charging and interchange station, the method comprising: determining, by a system for thermal management of electrical energy storage devices (BTMS), if at least one electrical energy storage device is present in a dock in the battery charging and interchange station; measuring, by the BTMS, a maximum temperature (Btmax) and computing an average temperature (Btavg) of the at least one electrical energy storage device present in the battery charging and interchange station; activating, by the BTMS, the dock pump (162) if the maximum temperature (Btmax) is greater than or equal to a max temperature threshold and the average temperature (Btavg) is greater than or equal to an average temperature threshold; anddeactivating, by the BTMS, the dock pump (162) if the maximum temperature (Btmax) is less than the max temperature threshold or the average temperature (Btavg) is less than the average temperature threshold.

20. A method for controlling solenoid valves in a system (100) for thermal management of electrical energy storage devices (EESD) in a battery charging and interchange station, the method comprising: determining, by a system for thermal management of electrical energy storage devices (BTMS), if at least one electrical energy storage device (EESD) is present in a dock in the battery charging and interchange station; determining, by the BTMS, if a dock pump (162) associated with the dock is healthy; opening, by the BTMS, a primary solenoid valve (164) and closing a secondary solenoid valve (166) if the dock pump (162) is healthy and activated; and closing, by the BTMS, the primary solenoid valve (164) and opening the secondary solenoid valve (166) if the dock pump (162) has failed or is deactivated.

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