Battery Control Device Adjusting Lower-Limit SOC to Prevent Slip

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Solution Overview

Problem

The challenge is to prevent secondary battery slipping in motor-driven vehicles without reducing the service range or increasing manufacturing costs, as the volume of secondary batteries decreases due to deterioration, requiring a balance between maintaining the battery pack's load and avoiding excessive clamping force that raises component costs.

Innovation Solution

A control device with a monitoring sensor and electronic control unit that calculates the state-of-charge variation to adjust the lower-limit state of charge, ensuring the battery pack operates within a range that maintains the necessary load without unnecessarily increasing the clamping force, thereby avoiding excessive component stress and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the clamping load is increased to prevent battery slipping when volume decreases due to deterioration, then the reliability of preventing battery slip is improved, but the manufacturing cost increases due to higher withstanding load and creep resistance requirements for components

Engineering Contradiction:
Improvebattery slip preventionVSAvoidmanufacturing cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies dynamics by dynamically adjusting the lower-limit SOC based on the calculated volume decrease of the secondary battery. Instead of using a fixed clamping load designed for maximum volume decrease scenarios, the system adapts the operational parameters (lower-limit SOC) according to the actual battery volume, which correlates with the rate of decrease of full charging capacity. This allows the clamping load to be optimized for current battery conditions rather than worst-case scenarios, reducing manufacturing costs while maintaining slip prevention reliability.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent changes the parameter of lower-limit SOC based on the calculated volume decrease. By storing information indicating the relationship between volume decrease and lower-limit SOC, and adjusting the lower-limit SOC accordingly, the system optimizes the operational range to account for battery deterioration. This parameter adjustment allows the battery to operate safely within reduced volume conditions without requiring increased clamping load, thereby avoiding higher manufacturing costs.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If the lower-limit SOC is increased in advance to account for volume decrease due to deterioration, then the reliability of preventing battery slip is improved, but the service range of the battery pack is narrowed

Engineering Contradiction:
Improvebattery slip preventionVSAvoidservice range
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent applies dynamics by adjusting the lower-limit SOC dynamically based on the actual volume decrease calculated from the rate of decrease of full charging capacity, rather than setting a fixed high lower-limit SOC in advance. This dynamic adjustment allows the service range to be maintained as large as possible while still preventing battery slip, as the lower-limit SOC is only increased when and if volume decrease actually occurs.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent uses feedback by calculating the volume decrease based on the rate of decrease of full charging capacity (obtained from monitoring sensors) and adjusting the lower-limit SOC accordingly. This feedback mechanism ensures that the lower-limit SOC is increased only when necessary, based on actual battery deterioration, rather than preemptively setting a high lower-limit SOC that would unnecessarily narrow the service range.

Inventive Principle:
Principle #23Feedback

3Reliability

If the clamping load is set for maximum volume decrease scenario, then the reliability of battery slip prevention is improved, but the components experience excessive stress leading to potential damage

Engineering Contradiction:
Improvebattery slip preventionVSAvoidcomponent stress
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The patent applies dynamics by adjusting operational parameters (lower-limit SOC) based on actual battery volume conditions, which allows the clamping load to be optimized for current battery state rather than maximum volume decrease scenarios. This dynamic optimization reduces unnecessary stress on components while maintaining adequate slip prevention capability.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent avoids excessive action by not setting the clamping load for maximum volume decrease scenarios. Instead, it applies partial action by setting the clamping load appropriate for current battery volume conditions and adjusting the lower-limit SOC accordingly. This prevents components from experiencing excessive stress that would occur with over-designed clamping loads.

Inventive Principle:
Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution allows for the prevention of battery slipping while maintaining the service range and avoiding increased manufacturing costs by dynamically adjusting the lower-limit state of charge based on calculated state-of-charge variations, ensuring the battery pack operates effectively without excessive stress on components.

Implementation Method 1

a negative-electrode active material expands due to charging and a negative-electrode active material contracts due to discharging

Methodology Applied
Scientific EffectExpansion and contraction:

Data Source

PatentUS10935607B2Control device for secondary battery, control method of secondary battery, battery system, and motor-driven vehicle
Publication Date: 2021.03.02 TOYOTA JIDOSHA KK
  • US10935607B2 patent drawing
  • US10935607B2 patent drawing
  • US10935607B2 patent drawing

AI summary

In a control device for a secondary battery, the secondary battery includes a monitoring sensor that detects battery information. An electronic control unit is configured to store first information. The electronic control unit is configured to set a lower-limit state of charge. The electronic control unit is configured to calculate a value of a rate of decrease of a full charging capacity using a value of the full charging capacity and to calculate a value of a state-of-charge variation using the value of the rate of decrease of the full charging capacity and the first information. The electronic control unit is configured to increase the lower-limit state of charge when the value of the state-of-charge variation is greater than a threshold value and to maintain the lower-limit state of charge when the value of the state-of-charge variation is less than the threshold value.