Battery Pack Fan Control for DC-DC Converter Cooling
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Solution Overview
Problem
Existing battery packs face challenges in effectively cooling the DC-DC voltage converter and efficiently controlling the electric fan to maintain optimal temperature levels and power output.
Innovation Solution
A battery pack design with a housing that separates the battery module and DC-DC voltage converter, utilizing a heat exchanger for cooling battery cells and directing air to cool the converter, along with a microprocessor-controlled electric fan that adjusts speed based on temperature and power output to maintain optimal operational conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the DC-DC voltage converter and battery module are disposed in separate spaces within a common housing, then each component can be cooled independently, but the device complexity increases due to additional housing structures and cooling pathways
Solution Approach 1:
The housing is divided into a first space for the battery module and a second space for the DC-DC voltage converter, with separate cooling pathways for each component. This segmentation allows independent optimization of cooling for each heat-generating component while maintaining a unified housing structure.
Solution Approach 2:
The housing serves multiple functions: it provides structural containment for both the battery module and DC-DC voltage converter, defines separate cooling pathways for each component, and acts as a thermal management system. This multi-functionality reduces the need for additional specialized components.
2Temperature
If the electric fan operates at high speed continuously to cool both battery cells and DC-DC voltage converter, then temperature control is improved, but energy consumption increases
Solution Approach 1:
The electric fan speed is dynamically adjusted based on real-time temperature measurements from both the battery module and DC-DC voltage converter. The microprocessor monitors temperatures and modulates fan speed accordingly, allowing the system to use high speed only when necessary and reduce speed when temperature levels are acceptable, thereby optimizing energy consumption.
Solution Approach 2:
Temperature sensors provide continuous feedback to the microprocessor about the thermal state of the battery module and DC-DC voltage converter. This feedback loop enables the system to adjust fan operation based on actual cooling needs, preventing unnecessary energy consumption while maintaining effective temperature control.
3Temperature
If the air flow path is extended to cool both battery cells and DC-DC voltage converter sequentially, then cooling coverage is improved, but the pressure loss increases
Solution Approach 1:
The air flow path is segmented into two distinct cooling zones: a first cooling pathway for the battery module and a second cooling pathway for the DC-DC voltage converter. Each pathway has its own inlet, heat exchanger, and outlet, allowing air to cool each component sequentially without excessive pressure loss in a single extended path.
Solution Approach 2:
The cooling system utilizes spatial arrangement by disposing the battery module and DC-DC voltage converter in different spaces within the housing, with air flow moving through different dimensional pathways. This spatial separation allows efficient heat extraction from both components without requiring an excessively long linear flow path.
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
The solution effectively cools the DC-DC voltage converter and maintains appropriate temperature levels within the battery pack by optimizing the electric fan's operational speed, ensuring efficient heat management and power output.
Implementation Method 1
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 2
the air flowing from the heat exchanger toward the outlet aperture further cools the DC-DC voltage converter
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 of the battery pack housing
Data Source
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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 desired operational speed value of the electric fan based on the first temperature level, and a second desired operational speed value of the electric fan based on the second temperature level. The microprocessor selects the first desired operational speed value if the first desired operational speed value is greater than the second desired operational speed value.