EV Battery Thermal Setpoint Control for Adaptive Charging Modes
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Solution Overview
Problem
Conventional thermal management systems in electrified vehicles use a single fixed profile for all charging modes, leading to inefficient charging due to EVSE power limits, resulting in wasted energy, prolonged charging times, and reduced battery life.
Innovation Solution
An adaptive charging thermal optimization system that dynamically determines temperature setpoints based on charging parameters and EVSE type, using a control system to manage thermal components, optimizing battery conditioning to match available power and extend component life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single fixed thermal management profile is used for all charging modes, then the system is simple to implement, but charging efficiency deteriorates due to EVSE power limits
Solution Approach 1:
The thermal management system transitions from a static fixed profile to a dynamic adaptive profile that automatically adjusts temperature setpoints based on real-time charging mode detection. The control system identifies the charging mode (Level 1, Level 2, or DC fast charging) and selects appropriate thermal management parameters, enabling the system to optimize charging efficiency across different EVSE power limits without requiring complex manual configuration.
Solution Approach 2:
The system changes thermal management parameters (temperature setpoints, heating/cooling rates) based on the detected charging mode. For DC fast charging, more aggressive thermal conditioning is applied to enable higher charge acceptance, while for Level 1 charging, conservative thermal management is used. This parameter adaptation resolves the contradiction by allowing simple implementation through automated mode detection while achieving high charging efficiency through mode-specific optimization.
2Ease of operation
If a single fixed thermal management profile is used for all charging modes, then implementation is straightforward, but charging time increases due to EVSE power limits
Solution Approach 1:
The control system dynamically adapts thermal management behavior to the detected charging mode, automatically optimizing charging time without requiring user intervention. The system monitors charging parameters, identifies the EVSE type, and adjusts thermal conditioning strategies in real-time, maintaining ease of operation while significantly reducing charging time through mode-specific optimization.
Solution Approach 2:
The system uses feedback from charging mode detection to automatically adjust thermal management parameters. By continuously monitoring charging current and voltage characteristics, the control system identifies the charging mode and applies appropriate thermal profiles, eliminating the need for manual configuration while achieving optimal charging times for each EVSE type.
3Device complexity
If conventional fixed profile thermal management is used, then the system is simple to control, but energy waste increases
Solution Approach 1:
The control system changes thermal management parameters based on detected charging mode, applying aggressive thermal conditioning only when necessary (DC fast charging) and conservative conditioning for lower power modes. This parameter adaptation reduces energy waste by avoiding unnecessary heating or cooling while maintaining simple automated control through mode detection.
Solution Approach 2:
The system applies partial thermal management action appropriate to each charging mode rather than always using maximum conditioning. For Level 1 and Level 2 charging, the system uses milder thermal management, reserving aggressive conditioning for DC fast charging scenarios, thereby reducing overall energy waste while maintaining simple automated control.
4Productivity
If mode-specific thermal profiles are implemented, then charging efficiency improves, but device complexity increases
Solution Approach 1:
The system uses dynamic mode detection to automatically select appropriate thermal profiles, achieving high charging efficiency without requiring complex manual configuration. The control system adaptively switches between thermal management strategies based on real-time charging conditions, resolving the contradiction by making the system appear simple to operate while internally implementing mode-specific optimization.
Solution Approach 2:
The thermal management system serves itself by automatically detecting charging modes and selecting appropriate profiles without external intervention. This self-service capability achieves high charging efficiency through mode-specific optimization while maintaining simple operation, as the system autonomously manages its own complexity through automated mode recognition and profile selection.
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
Improves charging efficiency by reducing energy waste and extending component life, achieving faster charging times and lower warranty costs.
Implementation Method 1
a set of thermal management components each configured to thermally condition a high voltage battery system
Implementation Method 2
a measured temperature of the high voltage battery system
Data Source
AI summary
An adaptive charging thermal optimization system for an electrified vehicle includes a set of thermal management components each configured to thermally condition a high voltage battery system of the electrified vehicle and a control system configured to detect whether the electrified vehicle is plugged into electrified vehicle supply equipment (EVSE) and, in response to detecting that the electrified vehicle is plugged into the EVSE, determine a set of charging parameters and limits for the high voltage battery system and the EVSE, determine a type or mode of the EVSE, determine a temperature setpoint for the high voltage battery system based on the charging parameters and limits for the high voltage battery system and the EVSE and the type or mode of the EVSE, and control the set of thermal management components based on the determined temperature setpoint and a measured temperature of the high voltage battery system.