Dynamic Battery Charging Control for Thermal Management

Solution Overview

Problem

Current battery charging methods for electric vehicles generate excessive waste heat and have insufficiently dimensioned plug contacts for high-power charging, leading to reduced charging capacity and potential battery damage due to overheating.

Innovation Solution

A method that dynamically adjusts the charging power based on predicted and actual user availability, using user-defined and calculated charging durations to optimize charging efficiency and prevent premature completion, while managing waste heat within predetermined limits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high charging power is used to achieve fast charging, then charging speed is improved, but waste heat generation increases causing battery overheating

Engineering Contradiction:

Improvecharging speedVSAvoidbattery temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The charging power is dynamically adjusted based on real-time monitoring of battery temperature and state of charge. The system transitions from static charging power to dynamic power adjustment, increasing or decreasing charging power according to battery thermal conditions and remaining charging time requirements.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements closed-loop feedback control by continuously monitoring battery temperature, state of charge, and charging power consumption. This feedback information is used to adjust charging power in real-time, preventing overheating while maintaining optimal charging speed.

Inventive Principle:

Principle #23Feedback

2Temperature

If charging power is reduced to prevent battery overheating, then battery temperature is controlled, but charging duration is extended beyond predicted time

Engineering Contradiction:

Improvebattery temperatureVSAvoidcharging duration

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The system calculates a predicted charging duration at the start of charging based on battery state and charging power capabilities. This predicted time serves as a reference for subsequent power adjustment decisions, allowing the system to proactively manage charging power to meet the predicted timeline while preventing overheating.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The charging power is dynamically adjusted based on real-time monitoring of battery temperature and state of charge. The system transitions from static charging power to dynamic power adjustment, increasing or decreasing charging power according to battery thermal conditions and remaining charging time requirements.

Inventive Principle:

Principle #15Dynamics

3Reliability

If charging is extended beyond predicted duration, then battery charge completeness is improved, but additional costs and penalties are incurred

Engineering Contradiction:

Improvecharge completenessVSAvoidcharging time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system calculates a predicted charging duration at the start of charging based on battery state and charging power capabilities. This predicted time serves as a reference for subsequent power adjustment decisions, allowing the system to proactively manage charging power to meet the predicted timeline while preventing overheating.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements closed-loop feedback control by continuously monitoring battery temperature, state of charge, and charging power consumption. This feedback information is used to adjust charging power in real-time, preventing overheating while maintaining optimal charging speed.

Inventive Principle:

Principle #23Feedback

4Power

If plug contacts are dimensioned for high charging power, then charging capacity is improved, but device complexity and cost increase

Engineering Contradiction:

Improvecharging powerVSAvoidplug contact dimensioning

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The charging power is dynamically adjusted based on real-time monitoring of battery temperature and state of charge. The system transitions from static charging power to dynamic power adjustment, increasing or decreasing charging power according to battery thermal conditions and remaining charging time requirements.

Inventive Principle:

Principle #15Dynamics

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

This approach enhances charging efficiency, prevents battery overheating, and ensures timely completion of the charging process, avoiding unnecessary costs and potential penalties, while maintaining the desired state of charge.

Implementation Method 1

When charging with direct current, high charging capacities are achieved, which lead to large amounts of waste heat when charging the batteries. This waste heat leads to heating of the entire battery, the electrical conductors and the battery environment.

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentEP4026728A1Charging method for battery, controller and battery management system

Publication Date: 2022.07.13 VOLKSWAGEN AG

Figure 1
Figure 2
Figure 3

AI summary

The present invention relates to a charging method for a vehicle battery, comprising: determining a predicted charging time; checking whether the predicted charging time is adhered to; adjusting the predicted charging time depending on the result of the test; and setting a charging power depending on the adjusted charging time.