Battery Management System Aging Prediction and Selective Replacement
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Solution Overview
Problem
Current battery systems in electric vehicles require the entire system to be replaced if a single battery cell fails, leading to high maintenance costs and inefficient replacement strategies, as individual modules or cells cannot be easily replaced, and there is a need for an optimized approach to determine the best time for replacement based on economic and environmental considerations.
Innovation Solution
A method that classifies the instantaneous and future aging states of battery units, using defined aging classes and a cost function to determine the optimal time for replacement, allowing for the possibility of replacing individual units or the entire system, and utilizing historical data for precise predictions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire battery system is replaced when a single battery cell fails, then the vehicle reliability is restored, but the maintenance cost increases significantly
Solution Approach 1:
The battery system is divided into multiple battery modules, each containing multiple battery cells. The management system can individually monitor and assess the state of charge and aging of each module, enabling selective replacement of only the defective module rather than the entire battery system. This segmentation allows for targeted maintenance that restores reliability while minimizing cost.
Solution Approach 2:
The system monitors multiple parameters including state of charge, temperature, and aging state of each battery module. By tracking these parameters over time and comparing them against threshold values, the system can predict which modules are likely to fail and schedule their replacement proactively, avoiding both premature replacement and failure-induced system downtime.
2Loss of energy
If individual battery modules or cells are replaced, then the maintenance cost is reduced, but the replacement process becomes more complex
Solution Approach 1:
The battery system is organized into modular units with standardized interfaces. Each battery module is designed as an independent replaceable unit, simplifying the replacement process. The management system provides detailed information about which specific modules need replacement, guiding technicians through a straightforward swap process rather than requiring complex diagnostics and reconfiguration.
Solution Approach 2:
The battery management system continuously monitors the state of each module and provides real-time feedback about module health and performance. This feedback includes identification of defective modules and predictions of future failures, enabling proactive scheduling of replacements during planned maintenance windows rather than emergency repairs, thus simplifying the overall replacement process.
3Loss of energy
If only defective battery modules are replaced, then the replacement cost is minimized, but frequent trips to the repair shop are required
Solution Approach 1:
The system performs preliminary assessment and prediction of battery module failures by continuously monitoring aging parameters and comparing them against historical data and thresholds. Before actual failures occur, the system identifies modules that are likely to fail within a certain time frame and schedules their replacement in advance during planned maintenance intervals, consolidating multiple potential replacements into single repair shop visits.
Solution Approach 2:
The battery management system operates continuously, monitoring all battery modules without interruption. This continuous monitoring enables the system to track the aging process of each module over time and predict failures before they occur, allowing for proactive scheduling of replacements that consolidates maintenance activities and reduces the frequency of repair shop trips.
4Reliability
If the entire battery system is replaced, then the long-term reliability is improved, but environmental impact increases due to waste
Solution Approach 1:
Instead of discarding the entire battery system when one module fails, the system selectively replaces only the defective modules while retaining and reusing the functional modules. This approach maximizes the utilization of existing battery components, reducing the amount of material waste and the environmental impact associated with manufacturing and disposing of entire battery systems. The retained modules continue to provide reliable service, maintaining long-term system reliability.
Data Source
AI summary
A method for operating a battery system in a vehicle that includes multiple battery units is described. The method includes classifying an instantaneous aging state of the battery units, first association of the battery units with instantaneous aging classes as a function of their instantaneous aging state, predicting a future aging state of the battery units for a future point in time, second association of the battery units with future aging classes as a function of their future aging state, ascertaining an optimal point in time for replacing battery units based on a cost function, taking into account the instantaneous aging classes and the future aging classes. A battery management system that is configured for carrying out the method is also described.