Traction Battery Cooling System with Predictive Thermal Buffering
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Solution Overview
Problem
The existing cooling systems for traction batteries in electric and hybrid vehicles are limited in their heat exchange capacity, leading to reduced charging rates and capacity during high-load conditions, especially in heavy vehicles, as they struggle to manage the thermal energy generated during rapid charging and high-load driving.
Innovation Solution
A method that utilizes a controller to analyze trip data and battery operating parameters to forecast temperature profiles, allowing for pre-activation of the cooling system and buffer-storing of cold energy before peak demand phases, thereby preventing battery temperature from exceeding safe limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooling system operates at maximum capacity during high-load driving, then the battery temperature can be maintained below the limit, but the charging rate and energy delivery are reduced due to temperature limitations
Solution Approach 1:
The cooling system is activated in advance during low-load phases (e.g., downhill driving, idle periods) to pre-cool the battery and store cold energy. This preliminary cooling action ensures that when high-load phases occur, the battery temperature remains below the limit, allowing maximum charging rates and energy delivery without thermal constraints.
Solution Approach 2:
The cooling system operates periodically rather than continuously, alternating between active cooling phases during low-load conditions and passive thermal management during high-load conditions. This periodic operation allows the battery to be cooled when thermal demand is low, then maintains acceptable temperatures through thermal inertia during high-demand phases, maximizing overall productivity.
2Productivity
If the cooling system capacity is increased to handle peak thermal loads, then the battery can maintain high performance during high-load driving, but the system complexity and cost increase
Solution Approach 1:
The cooling system uses variable speed pumps and controllable valves that can dynamically adjust coolant flow rates based on real-time battery temperature and load conditions. This dynamic control allows a smaller, simpler cooling system to achieve the same thermal management effect as a larger fixed-capacity system, reducing overall system complexity while maintaining high energy delivery capability when needed.
Solution Approach 2:
The system changes operational parameters (coolant flow rate, pump speed, valve positions) in response to varying thermal demands rather than maintaining constant maximum capacity. This parameter adjustment allows the cooling system to provide adequate cooling during peak loads without requiring oversized components, thereby reducing system complexity and cost.
3Reliability
If the battery is cooled continuously to maintain optimal temperature, then the battery efficiency is maximized, but energy is wasted during low-load phases when cooling is not needed
Solution Approach 1:
The cooling system incorporates temperature sensors and control logic that continuously monitor battery temperature and adjust cooling activation accordingly. Cooling is activated only when temperature thresholds are exceeded or during predicted high-load phases, and deactivated during low-load phases or when temperatures are already optimal, minimizing energy waste while maintaining battery efficiency and reliability.
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 approach effectively reduces the risk of battery overheating by optimizing the cooling system's operation, ensuring continuous high-performance energy delivery during high-load conditions by proactively managing thermal energy through strategic cooling strategies.
Implementation Method 1
buffer-storing cold energy while traveling the planned route by utilizing heat storage capacities of the traction battery before the phase of cooling output demand exceeding the threshold
Implementation Method 2
An energy exchange takes place by way of coolants, air or refrigerants
Data Source
AI summary
A method for operating a motor vehicle with a cooling system for cooling a traction battery may include receiving trip data representative of a planned route, reading in operating parameters of the traction battery, evaluating the trip data and the operating parameters to determine a set of data representative of a forecast temperature profile of the battery temperature, evaluating the set of data for the forecast temperature profile of the battery temperature to determine a phase of particularly high demand for cooling output while completing the route, buffer-storing (reducing) thermal energy while traveling the planned route by operating or increasing operation of the cooling system in anticipation of the high battery load to utilize heat storage capacity of the traction battery before the phase of particularly high cooling output demand.