Coolant Loss Detection in Liquid Cooled Battery Packs
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Solution Overview
Problem
Current liquid-cooled battery systems in vehicles lack effective early detection and automated corrective measures for coolant leaks, which can lead to unintended electrical discharges and thermal issues, potentially causing damage over a latency period following an accident or incident.
Innovation Solution
A method and system that utilize a coolant level sensor and a controller to detect coolant leaks by monitoring switch signals within sampling windows, incrementing failure counters, and reporting a Diagnostic Trouble Code and illuminating a Malfunction Indicator Light when thresholds are exceeded, with remedial actions including disabling charging and propulsion circuits to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coolant level monitoring is implemented, then early detection of coolant leaks is improved, but device complexity increases
Solution Approach 1:
A coolant level sensor acts as an intermediary device that detects coolant levels and sends signals to the controller. This mediator approach allows the system to monitor coolant levels without requiring complex direct measurement mechanisms, thereby improving reliability while minimizing added complexity.
Solution Approach 2:
The controller receives feedback signals from the coolant level sensor and automatically responds by setting fail counters and triggering alerts. This closed-loop feedback mechanism enables early detection and automated response to coolant leaks, enhancing reliability through continuous monitoring and automatic corrective actions.
2Object-affected harmful factors
If automated remedial actions are implemented, then prevention of electrical discharge damage is improved, but device complexity increases
Solution Approach 1:
The system performs preliminary actions by pre-programming the controller with remedial actions to be taken when coolant leaks are detected. The controller is configured in advance to disable charging and propulsion circuits, so when a leak is detected, the predetermined protective actions are automatically executed, preventing electrical discharge damage without requiring complex real-time decision-making systems.
Solution Approach 2:
The system applies preliminary anti-action by disabling the charging and propulsion circuits before electrical discharge damage can occur. When coolant leakage is detected, the controller proactively disables these circuits, creating a protective barrier against potential harmful electrical discharges, thereby preventing damage before it can manifest.
3Measurement precision
If continuous monitoring with multiple sampling windows is implemented, then detection precision is improved, but use of energy increases
Solution Approach 1:
The controller monitors coolant levels using periodic sampling windows rather than continuous monitoring. By checking coolant levels at discrete time intervals (multiple sampling windows), the system achieves sufficient detection precision to identify leaks while consuming less energy compared to continuous monitoring, as the sensor and controller are active only during these periodic sampling periods.
Data Source
AI summary
An automotive battery module with one or more battery cells and a coolant loss detection and remediation system cooperative with coolant that is configured to provide thermal management of the battery module. Coolant levels in or around the battery module may be detected, while cooperation with a controller permits corrective action in the event that a leakage of coolant is detected. The controller senses a coolant level sensor which is located in a coolant reservoir to determine when the coolant level drops below a predetermined level. When the coolant level is determined to be low, the controller reports the low level condition and takes remedial action. The controller also has a set of enablement conditions that must be satisfied before the controller senses the coolant level sensor.