Battery Cooling Pump Speed Optimization via Thermal Model
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Solution Overview
Problem
Conventional battery thermal management systems for battery backup units in data centers are insufficient in controlling temperature variations, leading to performance deterioration and potential failure due to delayed feedback and high energy consumption.
Innovation Solution
A controller-based system that optimizes liquid pump speeds in a battery cooling system using a thermal and flow characterization method, determining pump speeds based on battery discharge current and coolant temperature without real-time battery temperature feedback, to maintain temperature below a threshold and minimize energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional battery thermal management systems use real-time temperature feedback control, then temperature control accuracy is improved, but system complexity and response latency increase
Solution Approach 1:
The patent introduces an intermediary thermal model that predicts battery temperature based on discharge current and coolant temperature, avoiding the need for complex real-time temperature sensing and feedback systems. This mediator translates easily measurable parameters into temperature predictions, resolving the contradiction between control accuracy and system complexity.
Solution Approach 2:
The patent replaces the mechanical/physical temperature sensing and feedback system with a computational thermal model that calculates temperature predictions based on electrical parameters (discharge current) and coolant conditions. This substitution eliminates the need for complex temperature measurement and feedback infrastructure while maintaining control accuracy.
2Temperature
If liquid pump speeds are increased to improve cooling efficiency, then temperature control is improved, but energy consumption increases
Solution Approach 1:
The patent dynamically adjusts liquid pump speeds based on real-time discharge current conditions. During high discharge periods when cooling demand is high, pump speeds are increased. During low discharge periods, pump speeds are reduced. This dynamic adaptation optimizes the balance between cooling efficiency and energy consumption.
Solution Approach 2:
The patent changes the operational parameters of the liquid pump system based on thermal model predictions. By adjusting pump speed as a variable parameter in response to changing battery conditions (discharge current), the system achieves optimal cooling efficiency while minimizing energy consumption during different operational states.
3Measurement precision
If multiple temperature sensors are installed in the battery pack, then temperature measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the temperature measurement function from physical temperature sensors and relocates it to a thermal model computation. Instead of measuring temperature directly with multiple sensors, the system extracts temperature predictions from the thermal model using discharge current and coolant temperature as inputs, eliminating the need for multiple temperature sensors while maintaining measurement precision.
Solution Approach 2:
The patent creates a virtual copy of the battery thermal state through the thermal model, which replicates temperature behavior without requiring physical temperature sensors. This virtual temperature copy is generated by computing based on discharge current and coolant conditions, providing accurate temperature information without the complexity of multiple physical sensing elements.
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 reduces latency in temperature control, ensures battery performance within safe temperature limits, and optimizes energy usage by minimizing power consumption while maintaining battery health and performance.
Implementation Method 1
a liquid-to-liquid heat exchanger configured to transfer heat from the first liquid coolant into the second liquid coolant
Implementation Method 2
a first liquid pump that is configured to push the first liquid coolant that at least partially submerges the battery cells
Implementation Method 3
a second liquid pump that is configured to push the second liquid coolant into a cold side of the liquid-to-liquid heat exchanger
Implementation Method 4
the first liquid coolant that at least partially submerges the battery cells and is warmed by heat generated by the battery cells
Data Source
AI summary
According to one embodiment, a battery cooling system includes a battery module with cells, liquid pumps, and a heat exchanger. A method, in response to the battery module discharging battery energy, sets a first liquid pump that is configured to push a first liquid coolant warmed by heat generated by the cells into a hot side of the heat exchanger to a first pump speed, and sets a second liquid pump that is configured to push a second liquid coolant into a cold side of the heat exchanger to a second pump speed. The method determines at least one of an adjusted first and second pump speeds by optimizing an objective function based on the first and second pump speeds, a battery discharge current, and a temperature of the second liquid coolant. The objective function is to minimize the power consumption of the system's cooling components which are the first and the second pumps according to one embodiment. The method modifies at least one of the first and second pump speeds according to the adjusted speeds.