Dynamic SOC Operating Window Adjustment for Battery Packs

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Solution Overview

Problem

The challenge in accurately determining the state-of-charge (SOC) operating window of a battery pack assembly in vehicles leads to inefficient and potentially damaging usage, reducing the battery's lifespan and energy availability due to inaccurate SOC measurements and uneven charge distribution.

Innovation Solution

A method that determines an adjusted SOC operating window based on energy throughput or electrical current throughput, adjusting the window margins to reflect the accuracy of SOC estimation, thereby maintaining the battery within safe operational limits and optimizing energy use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the battery pack is used with a significant margin to the SOC limits to avoid damage, then the reliability and lifespan of the battery pack is improved, but the energy available in the battery and vehicle range is reduced

Engineering Contradiction:
Improvebattery pack lifespanVSAvoidenergy available in battery
Core Design Contradiction:
ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent applies dynamics by making the SOC operating window adjustable rather than fixed. The control unit dynamically adapts the SOC limits based on measured uneven charge distribution among battery cells. When uneven distribution is detected, the operating window is restricted to prevent harmful conditions; when distribution is even, the window can be expanded to maximize energy utilization. This resolves the contradiction by allowing the system to maintain reliability only when necessary while maximizing energy availability when safe.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent changes the parameters of the SOC operating window based on the state of charge distribution among battery cells. The control unit monitors the SOC of individual cells and adjusts the overall pack SOC limits accordingly. This parameter adaptation allows the system to optimize between safety margins and energy availability, restricting the window only when cell imbalances exist and allowing broader operation when cells are evenly charged.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If the SOC operating window is restricted to ensure safe operation, then the battery pack reliability is improved, but the vehicle range and energy utilization is reduced

Engineering Contradiction:
Improvebattery pack safetyVSAvoidvehicle range
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent implements a dynamic SOC operating window that adapts to the real-time charge distribution state of battery cells. The control unit continuously monitors individual cell SOC levels and adjusts the permissible operating window accordingly. This dynamic approach ensures safety by restricting operation when cell imbalances exist, while maximizing vehicle range by allowing broader SOC utilization when cells are evenly charged, thus resolving the contradiction between safety and productivity.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The battery management system performs self-service by autonomously monitoring its own internal state (cell charge distribution) and automatically adjusting its operating parameters (SOC window) without external intervention. This self-regulation ensures the system maintains safe operation while optimizing its own performance and range, eliminating the need for conservative fixed limits.

Inventive Principle:
Principle #25Self-service

3Measurement precision

If the SOC estimation is performed with high accuracy requirements, then the measurement precision is improved, but the device complexity and control difficulty increases

Engineering Contradiction:
ImproveSOC estimation accuracyVSAvoidcontrol system complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex physical measurement systems with an electronic control-based estimation approach. Instead of using additional sensors or complex hardware to directly measure individual cell SOC with high precision, the system uses a control unit to calculate and estimate SOC based on electrical parameters (voltage, current, temperature) and battery characteristics. This substitution achieves accurate SOC determination while avoiding the complexity of additional measurement hardware.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The control unit acts as an intermediary that processes electrical measurements and battery model data to estimate individual cell SOC levels. Rather than directly measuring each cell's charge state with complex instrumentation, the control unit uses electrical parameters and algorithms to infer SOC, providing accurate information with simpler means and enabling appropriate operating window adjustment.

Inventive Principle:
Principle #24Intermediary (Mediator)

Data Source

PatentUS11440433B2Method for determining a state-of-charge operating window of a battery
Publication Date: 2022.09.13 VOLVO TRUCK CORP
  • US11440433B2 patent drawing
  • US11440433B2 patent drawing
  • US11440433B2 patent drawing

AI summary

The invention relates to a method (100) for determining an adjusted state-of-charge (SOC) operating window of a battery pack assembly in a vehicle. The method comprises the steps of determining (120) an energy throughput or an electrical current through put of the battery pack assembly; determining (130) a SOC operating window margin based on said determined energy throughput or electrical current through put of the battery pack assembly;adjusting (140) the SOC operating window in response to the determined SOC operating window margin.