Charging-Station Thermal Imaging for EV Battery Runaway Prediction

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Solution Overview

Problem

Existing methods for monitoring thermal runaway in electric vehicle batteries are ineffective in predicting thermal runaway before it occurs, leading to potential damage or explosion of the battery during charging.

Innovation Solution

A system comprising a thermal camera integrated with an electric vehicle charging station, which uses a Kalman filter algorithm to predict thermal runaway by monitoring temperature changes during charging and comparing them to a predefined temperature gradient.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional temperature monitoring methods are used during battery charging, then the monitoring system is simple and easy to implement, but thermal runaway cannot be predicted before it occurs

Engineering Contradiction:

Improvethermal runaway prediction capabilityVSAvoidmonitoring system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system performs preliminary action by establishing a temperature model before thermal runaway occurs and continuously comparing real-time temperature data against this model. The Kalman filter predicts future temperature states ahead of time, enabling early warning before thermal runaway happens, thus resolving the contradiction between reliability improvement and system complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback by continuously monitoring temperature changes, comparing them with the predefined temperature gradient model, and adjusting predictions accordingly. The Kalman filter uses feedback from temperature measurements to refine its predictions of future temperature states, enabling accurate thermal runaway prediction while maintaining a manageable system through intelligent algorithms.

Inventive Principle:

Principle #23Feedback

2Object-affected harmful factors

If no temperature prediction system is implemented, then the charging process is fast and uninterrupted, but thermal runaway causes battery damage or explosion

Engineering Contradiction:

Improvebattery damage preventionVSAvoidcharging speed

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The system applies preliminary anti-action by predicting thermal runaway before it occurs and taking preventive measures. The Kalman filter forecasts future temperature states and compares them against safety thresholds, enabling the system to interrupt charging before thermal runaway happens, thus preventing battery damage while minimizing impact on charging productivity through early warning.

Inventive Principle:

Principle #9Preliminary anti-action

3Reliability

If traditional monitoring detects thermal runaway, then detection is simple, but prevention is impossible as thermal runaway has already occurred

Engineering Contradiction:

Improvethermal runaway preventionVSAvoidtemperature change detection precision

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system replaces traditional mechanical temperature threshold monitoring with a predictive mathematical model using the Kalman filter. This substitution enables the system to predict future temperature states based on current trends and compare them against predefined safety gradients, achieving precise thermal runaway prediction before it occurs rather than simply detecting when thresholds are exceeded.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables early prediction and prevention of thermal runaway, thereby preventing battery damage, fires, or explosions during charging, while also providing an indication to the user or automatically shutting off the charging process.

Implementation Method 1

a thermal camera configured to determine a change in temperature of a battery of an electric vehicle

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS20250030252A1Determining thermal runaway in an electric vehicle battery

Publication Date: 2025.01.23 HONEYWELL INTERNATIONAL INC

AI summary

Devices, methods, and systems for determining thermal runaway in an electric vehicle battery are described herein. One device includes a thermal camera configured to determine a change in temperature of a battery of an electric vehicle as the battery is being charged by an electric vehicle charging station, and determine, based on the change in the temperature of the battery as the battery is being charged, whether thermal runaway will occur in the battery. An indication can be provided upon the thermal camera determining thermal runaway will occur in the battery.