Battery Pack Coolant Leak Detection Using Moisture Sensors
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Solution Overview
Problem
Coolant leaks in electric vehicle battery packs can lead to damage due to moisture exposure, necessitating swift detection to prevent short circuits and other hazards.
Innovation Solution
A system with sensors that detect changes in resistance or capacitance due to moisture exposure, controlling coolant circulation and alerting the driver, and optionally isolating affected areas to prevent further leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant circulation is continuously maintained to ensure thermal management, then battery temperature regulation is improved, but the risk of damage from coolant leaks increases
Solution Approach 1:
The system performs preliminary detection by continuously monitoring for coolant leaks using sensors that detect moisture or coolant presence in the battery pack housing. When a leak is detected before significant damage occurs, the system preemptively stops coolant circulation and activates alerts, preventing the harmful effects of coolant exposure to battery cells while maintaining thermal management during normal operation
Solution Approach 2:
The system implements feedback control by using sensors to continuously monitor the battery pack environment for coolant leaks. When a leak is detected, the controller receives feedback and automatically responds by stopping the coolant pump and activating warning systems. This closed-loop feedback mechanism allows the system to adapt coolant circulation based on real-time leak detection, ensuring thermal management when safe and preventing damage when leaks occur
2Loss of time
If leak detection sensitivity is increased to detect coolant leaks earlier, then detection speed is improved, but false alarms may increase
Solution Approach 1:
The system uses an intermediary substance or sensor mechanism that specifically detects coolant or moisture presence through electrical properties (conductivity, capacitance, or resistance changes). This intermediary detection method provides a reliable signal that distinguishes actual coolant leaks from other moisture sources, enabling early detection with high sensitivity while maintaining reliability by targeting specific coolant properties rather than generic moisture detection
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
Quickly identifies and mitigates coolant leaks, preventing damage to the battery pack and ensuring safety by stopping coolant flow and alerting the driver.
Implementation Method 1
at least one sensor positioned in the housing that is configured to generate and communicate to the controller a signal indicative of a change in resistance or capacitance when exposed to moisture
Implementation Method 2
at least one pump for circulating the coolant through the plurality of cold-plates
Implementation Method 3
a battery pack thermal management system configured to exchange heat with the plurality of battery cells, the battery pack thermal management system including a plurality of cold-plates through which a coolant circulates therethrough
Data Source
AI summary
A vehicle including a battery pack having a plurality of battery cells and a battery pack thermal management system configured to exchange heat with the plurality of battery cells. The battery pack thermal management system includes a plurality of cold-plates through which a coolant circulates therethrough for each of the plurality of battery cells, at least one pump for circulating the coolant through the plurality of cold-plates, and controller in communication with the pump. The battery pack includes at least one sensor is configured to generate and communicate to the controller a signal indicative of a change in resistance or capacitance when exposed to moisture, wherein upon receipt of the signal indicative of the change in resistance or capacitance from the at least one sensor, the controller is configured to cease operation of the at least one pump to cease circulation of the coolant through the plurality of cold-plates.