Battery Pack Cell Switching Control for Thermal and Aging Balance
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Solution Overview
Problem
Lithium ion batteries in electrified vehicles experience imbalances in state of charge, thermal distribution, and state of health due to manufacturing variations, temperature gradients, and environmental conditions, leading to reduced power delivery and accelerated aging.
Innovation Solution
A method and system utilizing switching units in battery cells, combined with GPS data for power prediction, model predictive control, and state estimation, to optimize the connection and disconnection of battery cells based on predicted power requirements and battery state, addressing thermal, power, and aging issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If complex cooling systems are incorporated to manage thermal imbalance, then temperature control is improved, but device complexity increases
Solution Approach 1:
The battery pack is divided into multiple temperature zones with independent control. Temperature sensors are placed at different locations (e.g., top, bottom, sides) to detect thermal variations in different segments. The cooling system is segmented into multiple independent cooling channels or zones that can be controlled separately, allowing localized cooling where needed rather than cooling the entire pack uniformly.
Solution Approach 2:
The cooling system transitions from a static, fixed configuration to a dynamic, adaptive system. Flow rates, cooling intensities, and active cooling zones are continuously adjusted based on real-time temperature measurements and predicted thermal behavior. The system can dynamically activate or deactivate specific cooling zones based on the actual thermal state of different battery regions.
2Object-affected harmful factors
If electrical power is reduced to manage high temperature, then thermal safety is improved, but power output decreases
Solution Approach 1:
The system performs preliminary thermal management by predicting future temperature rises based on current operating conditions, battery state, and environmental factors. Before critical temperature thresholds are reached, the system proactively adjusts cooling intensity, pre-cools specific zones, or modifies charge/discharge rates to prevent thermal runaway, thereby maintaining power output while ensuring thermal safety.
Solution Approach 2:
The system implements closed-loop feedback control where real-time temperature measurements from multiple sensors are continuously monitored and fed back to the control unit. Based on this feedback, the system dynamically adjusts cooling intensity, flow rates, and power management strategies to maintain temperatures within safe operating limits while maximizing power output. The feedback mechanism allows the system to respond to thermal changes and maintain both safety and performance.
Data Source
AI summary
A method for monitoring and controlling a vehicle battery pack that includes a plurality of battery cells. The battery cells each include a switching unit which serves to connect and disconnect the respective battery cells. Pack information of the battery pack is acquired, a pack voltage of the battery pack is calculated on the basis of the cell voltages and a current activation pattern for actuating the switching units. An electrical power requirement of the vehicle is predicted based on GPS information. A state of the battery pack is estimated based on the pack information and the current activation pattern and an optimized activation pattern for actuating the switching units on the basis of the predicted electrical power requirement and the estimated state of the battery pack is calculated. The switching units of the respective battery cells are actuated according to the optimized activation pattern.