Battery Pack Coolant Flow Inference via Inlet-Outlet Sensors
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Solution Overview
Problem
Current thermal management systems in electrified vehicles face challenges in accurately monitoring and managing coolant flow through battery packs and other components, leading to potential inefficiencies and malfunctions due to lack of real-time fluid condition monitoring.
Innovation Solution
Integration of sensors at the inlet and outlet of the battery pack, along with a control module, to monitor pressure and temperature conditions of the coolant, allowing for inference of coolant flow rates and fluid conditions, and the use of multiple cooling loops with radiators and pumps to manage thermal loads across various vehicle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal management systems use basic coolant circulation without real-time monitoring, then the system structure remains simple, but system integrity and reliability deteriorate due to inability to detect flow issues
Solution Approach 1:
The patent implements feedback by using sensors to continuously monitor coolant flow conditions and providing real-time data to a control module. The control module processes this feedback information and can adjust system operations or alert operators to flow issues, thereby maintaining system integrity through continuous monitoring and responsive control.
Solution Approach 2:
The patent replaces direct mechanical flow measurement devices with a control module that infers flow conditions from sensor data (pressure, temperature, flow rate sensors). This substitution reduces mechanical complexity while maintaining monitoring capability, as the control module processes electrical signals rather than requiring complex mechanical flow measurement mechanisms.
2Measurement precision
If no real-time fluid condition monitoring is implemented, then the system remains simple, but detection precision of flow issues deteriorates
Solution Approach 1:
The control module receives continuous feedback from multiple sensors monitoring fluid conditions including pressure, temperature, and flow rate. This feedback enables precise detection of flow issues by comparing real-time measurements against expected operational parameters, allowing for accurate identification of anomalies without requiring overly complex monitoring hardware.
Solution Approach 2:
The control module serves multiple functions: it processes data from various sensor types (pressure, temperature, flow rate), performs flow condition analysis, and can control system responses. This multi-functionality consolidates complexity into a single intelligent unit rather than requiring separate dedicated systems for each monitoring and control function.
3Measurement precision
If multiple sensors are integrated at inlet and outlet to monitor fluid conditions, then flow inference accuracy improves, but device complexity increases
Solution Approach 1:
The patent merges multiple sensor functions into integrated sensor assemblies positioned at the inlet and outlet of the battery pack. These integrated sensors simultaneously measure multiple parameters (pressure, temperature, flow rate) and consolidate their outputs to the control module, reducing the number of separate connection points and simplifying integration while maintaining comprehensive monitoring capability.
Solution Approach 2:
The control module acts as an intermediary that receives processed signals from multiple sensors and performs the complex task of inferring flow conditions. Rather than requiring direct complex interconnections between all sensors and all processing functions, the control module mediates between the sensor array and the control system, simplifying the overall architecture while enabling accurate flow inference through coordinated processing of multiple sensor inputs.
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
Enhances system integrity by providing real-time monitoring and control of coolant flow, preventing issues like leakage and blockages, and optimizing thermal management across components, thereby improving the reliability and efficiency of electrified vehicle systems.
Implementation Method 1
a first sensor configured to indicate a fluid condition of the coolant
Implementation Method 2
the first sensor and the second sensor are integrated pressure and temperature sensors
Implementation Method 3
a first cooling loop that circulates a coolant through the vehicle component
Implementation Method 4
manage the thermal demands of various components during vehicle operation
Data Source
AI summary
A battery system according to an exemplary aspect of the present disclosure includes, among other things, a battery pack, a first sensor at an inlet of the battery pack and a second sensor at an outlet of the battery pack.