Battery Thermal Runaway Detection Using Anomaly Dynamics
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Solution Overview
Problem
Current methods for detecting thermal runaway in electric energy storage units of motor vehicles are prone to errors, particularly due to unreliable insulation fault measurements and the high cost of additional sensors, as well as the limitations of temperature sensors in detecting cell temperature accurately.
Innovation Solution
A method using an electronic computing device to continuously monitor the electric energy storage unit through diagnostic methods, determining the frequency and dynamics of anomalies in the diagnostic signal, and generating a differential signal based on communication line anomalies to accurately detect thermal runaway without additional sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation fault measurement is used for thermal runaway detection, then detection capability is provided, but measurement reliability deteriorates due to errors
Solution Approach 1:
The patent combines multiple diagnostic signals (voltage, temperature, current, insulation resistance) into a unified diagnostic framework. Instead of relying on a single measurement method with inherent errors, the system integrates multiple signal sources to cross-validate and compensate for individual measurement deficiencies, thereby improving overall detection reliability while maintaining measurement precision through comparative analysis.
Solution Approach 2:
The system continuously monitors diagnostic signals and uses feedback loops to adjust detection thresholds and algorithms based on observed patterns. By analyzing the temporal behavior and consistency of insulation fault measurements against other sensor data, the system can distinguish true anomalies from measurement errors, improving both reliability and precision dynamically.
2Measurement precision
If additional sensors such as pressure sensors are integrated for thermal runaway detection, then detection accuracy is improved, but device cost increases
Solution Approach 1:
The patent makes existing sensors multi-functional by using them for multiple diagnostic purposes. For example, temperature sensors originally designed for battery monitoring are also utilized for thermal runaway detection by analyzing temperature gradients and rate-of-change patterns. This eliminates the need for dedicated additional sensors while maintaining high detection accuracy through sophisticated signal processing and pattern recognition algorithms.
Solution Approach 2:
The system uses the battery management system's existing infrastructure and sensors to perform thermal runaway detection without requiring external additional components. The BMS hardware and software are leveraged to their full potential, using available voltage, current, and temperature measurements in novel diagnostic combinations that provide accurate thermal runaway detection while avoiding increased device complexity and cost.
3Reliability
If temperature sensors are installed in each battery cell for thermal runaway detection, then detection capability is provided, but false warnings increase due to shielding issues and time lag
Solution Approach 1:
The system detects preliminary signs of thermal runaway through subtle changes in voltage, current, and temperature patterns before actual thermal runaway occurs. By monitoring the rate of change and anomalies in these parameters, the system can issue early warnings based on predictive patterns rather than waiting for temperature sensors to detect actual thermal events, thereby reducing time lag and avoiding false warnings from poorly positioned sensors.
Solution Approach 2:
Instead of relying solely on spatial temperature measurement (which suffers from shielding and positioning issues), the system transitions to temporal and differential analysis dimensions. By examining the time derivatives of temperature, voltage, and current, and analyzing patterns across multiple time scales, the system can detect thermal runaway signatures without being constrained by physical sensor placement, thereby eliminating shielding problems and reducing detection lag.
4Ease of operation
If cell voltage measurement is used for thermal runaway detection, then simplicity is maintained, but detection reliability deteriorates due to false warnings from measuring line breaks
Solution Approach 1:
The patent introduces intermediary diagnostic checks and validation layers between the raw voltage measurement and the thermal runaway determination. Instead of directly using voltage measurements as the sole criterion, the system employs intermediate analysis steps that cross-check voltage anomalies against other sensor data, temporal patterns, and plausibility criteria. This intermediary validation layer maintains system simplicity while filtering out false warnings from measuring line breaks or transient voltage fluctuations.
Data Source
AI summary
A method for determining a thermal runaway of an electric energy storage unit of an operated motor vehicle includes continuous monitoring of the electric energy storage unit by at least one diagnostic method of an electric energy storage unit based on a diagnostic signal, determining a frequency of the anomaly when the anomaly is detected in the diagnostic signal, determining dynamics of the anomaly when the anomaly is detected in the diagnostic signal, continuous monitoring of a communication line by a limited anomaly counter, comparing the limited anomaly counter with an unlimited anomaly counter when the anomaly is detected inside the communication line and generating a differential signal on the basis thereof, and determining the thermal runaway on the basis of the determined frequency and the determined dynamics and the differential signal.