Resilient Battery Cooling with Dual Isolated Power Strings
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Solution Overview
Problem
Conventional electric vehicle battery systems are vulnerable to thermal runaway and system failure due to the division of responsibilities between high-voltage and low-voltage batteries, which can lead to inoperability of the vehicle and potential safety hazards.
Innovation Solution
The implementation of two electrically isolated high-voltage power strings, each capable of powering the electrical distribution system, allows for redundant power supply and enables essential functions like battery cooling to continue even if one battery string fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If two separate battery subsystems (high-voltage and low-voltage) are used, then power output and vehicle performance are improved, but system reliability deteriorates because failure of either system results in inoperability of the entire vehicle
Solution Approach 1:
The battery system is segmented into two electrically isolated high-voltage power strings instead of separate high-voltage and low-voltage subsystems. Each string can independently power essential functions, so that if one string fails, the other can maintain vehicle operation and critical systems remain functional.
Solution Approach 2:
Each battery string is designed to be universal and capable of powering both high-voltage traction systems and essential low-voltage functions. The electrical distribution system can draw power from either string for multiple functions including cooling, climate control, and traction, eliminating the single-point-failure vulnerability of dedicated subsystems.
2Power
If high-voltage battery systems operate at higher voltages (e.g., 800V), then power output increases, but the risk of thermal runaway and heat propagation to adjacent cells increases
Solution Approach 1:
The battery system is divided into two electrically isolated power strings with physical and electrical separation. This segmentation limits thermal propagation pathways, so that if one string experiences thermal runaway, the other string remains isolated and protected, preventing cascading failure throughout the entire battery pack.
Solution Approach 2:
The electrical distribution system acts as an intermediary that can selectively connect or isolate battery strings from various loads including cooling systems. In the event of thermal events, the intermediary enables rapid disconnection of affected strings while maintaining power to critical systems through the healthy string.
3Temperature
If conventional battery cooling systems are used, then battery temperature control is achieved, but the cooling system may fail if the battery subsystem it depends on fails
Solution Approach 1:
The battery cooling system is designed as a universal load that can be powered by either battery string independently. The electrical distribution system is configured to supply power to the cooling system from whichever string is operational, ensuring that temperature control functionality is maintained even when one battery string fails.
Solution Approach 2:
The system incorporates redundant power supply paths for the cooling system before failure occurs. By pre-configuring the electrical distribution system to accept power from either battery string, the system cushions against potential cooling failure that would otherwise result from battery subsystem failure.
Data Source
AI summary
Systems and methods of thermal control in a resilient battery cooling system ensure that power is maintained to operate a cooler even when an event disables a battery cell. The cooler can therefore prevent thermal propagation from the affected cell to neighboring cells.