Adaptive Battery Pack SOC Windows for Route-Based Energy Demand

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Solution Overview

Problem

Existing battery management systems fail to effectively control the State-of-Charge (SOC) operating window of battery packs in electric vehicles, leading to potential deterioration of battery health due to operating outside restricted limits.

Innovation Solution

A computer system with processing circuitry determines extended or limited SOC limits based on battery health condition and predictive energy utilization, setting a fixed operating window to optimize energy storage and utilization while minimizing health deterioration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the battery pack operates within restricted SOC operating windows, then the battery health is protected from deterioration, but the available energy for usage is reduced

Engineering Contradiction:
Improvebattery healthVSAvoidavailable energy
Core Design Contradiction:
ReliabilityVSQuantity of substance

Solution Approach 1:

The patent applies dynamics by making the SOC operating window adaptive rather than fixed. The control system dynamically adjusts the SOC limits based on real-time battery health status, drive cycle requirements, and environmental conditions. This allows the system to expand the operating window when battery health permits and contract it when protection is needed, resolving the contradiction between health protection and energy availability.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent changes the parameters of the SOC operating window based on battery state-of-health (SOH) metrics. When SOH is high, the system allows broader SOC ranges including extended charging. When SOH degrades, the system automatically narrows the operating window to protect the battery. This parameter adaptation resolves the contradiction by adjusting energy availability according to actual battery condition.

Inventive Principle:
Principle #35Parameter changes

2Quantity of substance

If the battery pack operates outside the restricted SOC operating window, then more energy is available for usage, but the battery health deteriorates

Engineering Contradiction:
Improveavailable energyVSAvoidbattery health
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The patent implements preliminary action by predicting future battery health status and drive cycle requirements before making SOC window adjustments. The system uses predictive algorithms to anticipate when the battery will need protection or when extended energy availability is safe, allowing proactive rather than reactive window adjustment. This resolves the contradiction by preparing the optimal operating window in advance based on forecasted conditions.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent employs feedback mechanisms where the control system continuously monitors battery health metrics, actual energy utilization, and operating conditions. This feedback loop allows the system to learn from past operations and refine SOC window settings, ensuring that energy availability is maximized without causing harmful battery deterioration. The feedback resolves the contradiction by using actual performance data to optimize the trade-off.

Inventive Principle:
Principle #23Feedback

Data Source

PatentEP4663457A1A method for controlling the SOC operating window of a battery pack
Publication Date: 2025.12.17 VOLVO TRUCK CORP
  • EP4663457A1 patent drawingFigure 1
  • EP4663457A1 patent drawingFigure 2
  • EP4663457A1 patent drawingFigure 3

AI summary

A computer system (17) comprising processing circuitry (18) configured to: determine operating windows (140, 141, 142) of a battery pack (114) of an electric vehicle (1) defined by its state-of-charge, SOC, according to default predetermined SOC limits (140), extended predetermined SOC limits (142) and limited predetermined SOC limits (141); determine predictive energy or power utilization of the battery pack (114) for a predetermined route (301); determine a health condition of the battery pack (114); and in response to the determined health condition of the battery pack (114) and the determined predictive energy or power utilization of the battery pack (114) for the predetermined route (301), set a fixed operating window (140, 141, 142) of the battery pack (114) according to either the limited predetermined SOC limits (142), the default predetermined SOC limits (140), or the extended predetermined SOC limits (141).