High Voltage Battery Control Using Virtual Temperature Sensors
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Solution Overview
Problem
The minimization of temperature sensors in high voltage battery systems for electric and hybrid vehicles leads to significant control instability and potential battery degradation due to sensor failures, increasing production costs and risks of over-charging and over-discharging.
Innovation Solution
A method and apparatus for controlling high voltage batteries that involves monitoring two temperature sensors positioned to measure minimum and maximum temperatures within the battery pack, calculating a replacement temperature using a lookup table-based maximum temperature deviation, and updating measurements when a sensor fails to ensure stable battery control, thereby reducing the need for multiple sensors and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the number of temperature sensors is minimized to reduce production costs, then production cost is reduced, but reliability deteriorates due to sensor failure causing control instability
Solution Approach 1:
The patent pre-calculates and stores temperature deviation data in a lookup table during the design phase, representing temperature differences between various sensor positions under different ambient conditions. When a sensor fails, the controller immediately uses this pre-prepared data to calculate replacement temperatures without delay, maintaining reliable battery control with minimal sensors
Solution Approach 2:
The patent creates a virtual copy of the failed temperature sensor's measurement by calculating a replacement temperature based on the remaining functional sensor's data and the pre-stored temperature deviation characteristics. This virtual copy allows the control system to continue operating reliably even with physical sensor failure
2Ease of manufacture
If the number of temperature sensors is minimized to reduce production costs, then production cost is reduced, but measurement precision deteriorates due to inability to accurately represent battery temperature distribution
Solution Approach 1:
The patent transforms the temperature measurement problem by changing from direct physical measurement at multiple points to a calculated parameter approach. The controller measures ambient temperature and uses pre-stored temperature deviation characteristics to calculate the temperature at the failed sensor position, maintaining measurement precision without additional physical sensors
Solution Approach 2:
The patent introduces temperature deviation characteristics as an intermediary element that bridges the gap between the single functional sensor and the virtual representation of the failed sensor. These characteristics, stored in the lookup table, enable accurate temperature estimation at any position based on ambient temperature conditions
3Reliability
If multiple temperature sensors are used to maintain reliability and measurement precision, then battery control stability is improved, but production cost increases
Solution Approach 1:
The patent extracts and stores the essential temperature distribution characteristics (temperature deviations between positions) in a lookup table during the design phase. This extraction allows the system to operate reliably with fewer physical sensors during production, as the missing sensor data can be reconstructed from the stored characteristics and ambient temperature measurements
Solution Approach 2:
The patent performs preliminary characterization of the battery pack's thermal behavior by measuring temperature deviations at various positions under different ambient conditions and storing this data in advance. This preliminary action enables the system to compensate for sensor failures using calculation rather than requiring redundant physical sensors
Data Source
AI summary
An apparatus and method are provided for controlling a high voltage battery within vehicle. The apparatus monitors states of a first temperature sensor and a second temperature sensor mounted within a battery pack and calculates a replacement temperature that corresponds to the faulty temperature sensor using a temperature deviation within the battery pack for each ambient temperature of the battery when a faulty temperature sensor of the first temperature sensor and the second temperature sensor is detected. The replacement temperature is then used to operate the battery, and thus the stability of the battery control is improved even though the temperature sensor of the battery fails.