Battery Pack Fan Control Using Dual Temperature Sensors
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Solution Overview
Problem
Existing battery packs lack an efficient method to control the electric fan's speed based on the temperature levels of both battery cells and DC-DC voltage converters, leading to suboptimal cooling performance.
Innovation Solution
A battery pack design that includes a microprocessor coupled with temperature sensors for both battery cells and DC-DC voltage converters, determining and selecting the highest fan speed percentage value to control the electric fan's operational speed, ensuring effective cooling by optimizing airflow through the pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single temperature sensor is used to control fan speed, then the control system is simple, but the cooling performance is suboptimal because it cannot account for temperature variations in different components
Solution Approach 1:
The patent implements separate temperature sensors positioned at specific locations near the battery module and DC-DC voltage converter. Each sensor monitors the temperature of its respective component, enabling localized temperature-based control decisions. This allows the fan speed to be optimized for each component's specific thermal conditions rather than using a single generic temperature reading.
Solution Approach 2:
The control system dynamically adjusts fan speed based on real-time temperature readings from multiple sensors. The microprocessor continuously monitors temperature data and adjusts the fan's operational speed accordingly, creating a dynamic response to changing thermal conditions. This enables the system to adapt fan speed to the most critical component's needs at any given moment.
2Reliability
If fan speed is constantly maximized to ensure adequate cooling, then cooling performance is maintained, but energy consumption increases
Solution Approach 1:
The fan operates dynamically with variable speed rather than at constant maximum speed. The microprocessor adjusts fan speed in real-time based on actual temperature measurements, increasing speed only when and where needed to maintain adequate cooling. This dynamic operation reduces unnecessary energy consumption during periods when maximum cooling is not required.
Solution Approach 2:
The system changes the operational parameters of the fan based on thermal conditions. Instead of maintaining a fixed high speed, the fan speed parameter is adjusted according to the most critical temperature reading, allowing the system to consume only the energy necessary to maintain safe operating temperatures.
3Reliability
If separate cooling systems are provided for battery cells and DC-DC voltage converter, then each component is optimally cooled, but the system complexity and space requirements increase
Solution Approach 1:
The cooling system is designed to serve multiple functions through a single integrated airflow path. The same fan and air passage structure provide cooling for both the battery module and DC-DC voltage converter, eliminating the need for separate cooling systems. The system achieves component-specific cooling by strategically positioning temperature sensors and using the airflow path to reach both components, thereby reducing overall system complexity while maintaining effective cooling for each component.
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 solution enhances cooling efficiency by dynamically adjusting the fan speed based on temperature levels, thereby improving the overall performance and longevity of the battery pack.
Implementation Method 1
The battery module has at least one battery cell disposed against a heat exchanger
Implementation Method 2
The heat exchanger is configured to receive air that enters the first interior space from the inlet aperture to cool the at least one battery cell
Implementation Method 3
The electric fan is adapted to urge the air to flow from the inlet aperture through the first and second interior spaces to the outlet aperture
Data Source
AI summary
A battery pack is provided. The battery pack includes first and second temperature sensors that are disposed in first and second interior spaces, respectively. The first temperature sensor generates a first signal indicative of a first temperature level of the battery cell. The second temperature sensor generates a second signal indicative of a second temperature level of the DC-DC voltage converter. The battery pack further includes a microprocessor that determines a first fan speed percentage value of the electric fan based on the first temperature level, and a second fan speed percentage value of the electric fan based on the second temperature level. The microprocessor selects the first fan speed percentage value if the first fan speed percentage value is greater than the second fan speed percentage value.