Battery Cell Voltage Windowing for Early Thermal Runaway Warning

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Solution Overview

Problem

Existing methods for detecting thermal runaway risk in electric vehicles based on overall battery parameters are timeliness, leading to delayed battery replacement and increased risk of thermal runaway.

Innovation Solution

A method that involves obtaining cell voltage data, dividing it into time windows, extracting cell voltage characteristics, and determining thermal runaway risk based on preset voltage warning conditions, including deviation values and discrete degrees, to trigger timely warning alerts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If overall battery parameters are used for thermal runaway detection, then the detection method is simple, but the timeliness of warning is low

Engineering Contradiction:

Improvedetection method simplicityVSAvoidwarning timeliness

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent divides the battery pack into multiple battery modules, and each module is further divided into multiple time windows for analysis. This segmentation allows the system to detect thermal runaway risks at the cell level within specific time periods, enabling earlier and more precise warnings compared to overall battery parameter detection.

Inventive Principle:

Principle #1Segmentation

2Reliability

If overall battery parameters are used for thermal runaway detection, then the detection scope is comprehensive, but the warning timeliness is delayed

Engineering Contradiction:

Improvedetection coverageVSAvoidwarning delay

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent segments the battery pack into multiple modules and analyzes each module's cell voltage data separately within divided time windows. This approach maintains comprehensive detection coverage across the entire battery while enabling earlier detection of localized thermal runaway risks, thus reducing warning delay.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a time window dimension to the detection process, analyzing cell voltage data within specific time periods rather than using overall historical data. This dimensional change enables the system to identify rapid voltage changes indicative of thermal runaway earlier, improving warning timeliness while maintaining comprehensive monitoring.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Loss of time

If cell level detection is implemented, then the warning timeliness is improved, but the system complexity increases

Engineering Contradiction:

Improvewarning timelinessVSAvoiddetection system complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The patent divides the battery pack into multiple modules and each module into time windows, creating a hierarchical segmentation structure. This approach enables cell-level detection with improved timeliness while managing complexity through structured organization of data processing at different levels (module level and time window level).

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies detection algorithms to partial cell voltage data within specific time windows rather than processing all cell data continuously. This partial action approach maintains high warning timeliness by focusing computation on relevant time periods and modules, thereby reducing overall system complexity.

Inventive Principle:

Principle #16Partial or excessive action

4Measurement precision

If cell voltage characteristics are analyzed in detail, then the detection accuracy is improved, but the computational complexity increases

Engineering Contradiction:

Improvedetection accuracyVSAvoidcomputational complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent analyzes cell voltage characteristics within partial time windows rather than processing the entire data history. This approach improves detection accuracy by focusing on recent voltage changes that indicate thermal runaway risk, while reducing computational complexity by limiting the analysis scope to relevant time periods and voltage intervals.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The patent transforms cell voltage data into voltage deviation values and discrete degree parameters within specific time windows. This parameter transformation enables accurate detection of thermal runaway trends while simplifying computational processing by working with derived parameters rather than raw voltage data.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12479299B2Vehicle thermal runaway warning method, device, electronic equipment, and readable storage medium

Publication Date: 2025.11.25 ZHEJIANG ZEEKR INTELLIGENT TECH CO LTD

AI summary

Disclosed herein are a vehicle thermal runaway warning method, device, electronic equipment and readable storage medium. The method of vehicle thermal runaway warning includes obtaining operating data of a vehicle, the operating data including a plurality of cell voltage data of a battery pack in the vehicle, and dividing time windows for the plurality of cell voltage data according to a collection timing of the operating data. The method also includes extracting cell voltage characteristics from a partial cell voltage data corresponding to each of the divided time windows. The method further includes, in response to each cell voltage characteristic meeting a preset voltage warning condition, determining that the vehicle has a risk of thermal runaway, and controlling the vehicle to output thermal runaway warning information.