EV Battery Thermal Preconditioning for Faster Roadside Charging

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Solution Overview

Problem

Conventional electrified vehicle charging techniques are inefficient, leading to increased charging time and costs due to suboptimal battery temperature and state of charge conditions, and do not adapt to real-time and historical information or charging station availability, resulting in prolonged stoppage times and energy wastage.

Innovation Solution

A charging session optimization system that uses sensors to monitor the battery's temperature and state of charge, and a controller to thermally precondition the battery en route to a charging station based on real-time and a priori information, including climate, traffic, and charging station parameters, to ensure optimal charging conditions and minimize energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional charging techniques are used without thermal preconditioning, then the charging system is simple and easy to operate, but the charging time is prolonged and efficiency is reduced

Engineering Contradiction:

Improvecharging efficiencyVSAvoidcharging time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system performs thermal preconditioning of the battery before charging by adjusting the operation of the electrified powertrain or controlling the thermal management system during the period up until the future charging session begins, ensuring the battery reaches optimal temperature and state of charge ranges for efficient charging

Inventive Principle:

Principle #10Preliminary action

2Temperature

If thermal preconditioning is performed using the thermal management system, then the battery temperature is optimized for charging, but energy consumption increases

Engineering Contradiction:

Improvebattery temperatureVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The controller adjusts operation of the electrified powertrain to thermally precondition the battery by changing operational parameters such as motor load and regenerative braking, utilizing waste heat from the powertrain to heat the battery or reducing load to allow passive cooling, thereby optimizing battery temperature with minimal additional energy consumption

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system utilizes waste heat generated by the electrified powertrain during operation to thermally precondition the battery, converting what would otherwise be wasted thermal energy into a beneficial resource for heating the battery to optimal charging temperature

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Loss of energy

If the battery is not thermally preconditioned, then energy consumption is lower, but charge acceptance is reduced and charging costs increase

Engineering Contradiction:

Improveenergy wasteVSAvoidcharge acceptance

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

The charging session optimization system uses sensors to monitor real-time battery parameters including temperature and state of charge, and the controller uses this feedback information to dynamically adjust the thermal preconditioning strategy, optimizing the balance between energy consumption and charge acceptance by continuously adapting to actual battery conditions

Inventive Principle:

Principle #23Feedback

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 enables faster charging sessions, reduces total stoppage time, maximizes charge acceptance throughout the charging event, minimizes energy consumption and costs, and ensures the battery is at an optimal temperature for efficient charging, thereby improving the overall efficiency and acceptance of electrified vehicles.

Implementation Method 1

a thermal management system of the electrified vehicle that is configured to heat/cool the high voltage battery system

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a thermal management system of the electrified vehicle that is configured to heat/cool the high voltage battery system

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS20240326650A1Systems and methods for en route proactive thermal conditioning of electrified vehicle batteries to reduce charging and stoppage time

Publication Date: 2024.10.03 FCA US LLC

AI summary

Charging session optimization systems and methods for an electrified vehicle involve determining a target roadside charging station intended to be used for a future charging session to recharge a high voltage battery system of the electrified vehicle, receiving a set of real-time charging information including at least a temperature and a state of charge (SOC) of the high voltage battery system, and thermally preconditioning the high voltage battery system during a period up until the future charging session begins based on at least the temperature and the SOC of the high voltage battery system, wherein the thermal preconditioning of the high voltage battery system is performed such that its future temperature and future SOC at an end of the period when the future charging session begins are each within predetermined ranges associated with an optimal rate of recharging.