EV Battery Thermal Conditioning for Efficient Charging
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Solution Overview
Problem
Hybrid-electric vehicles face inefficiencies in charging their traction batteries, particularly due to increased fuel consumption when using an internal combustion engine for recharging, and the need to manage battery temperature for optimal charging conditions.
Innovation Solution
A vehicle system that includes an electric machine for power exchange with the traction battery, a thermal conditioning system to manage battery temperature, and a controller that schedules charging based on battery state of charge, accessory power demands, and user-selected modes to optimize engine output for efficient battery charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the engine is operated to charge the traction battery, then the battery state of charge increases, but fuel consumption increases
Solution Approach 1:
The system performs preliminary thermal conditioning of the battery before charging operations. The controller activates the thermal conditioning system to bring the battery temperature within the optimal charging range (0°F to 104°F) before initiating engine-based charging, thereby preparing the battery to receive charge more efficiently and reducing the overall energy required for the charging process
Solution Approach 2:
The system dynamically adjusts engine operating parameters and charging rates based on real-time battery temperature conditions. When the battery temperature is within the optimal range, the system allows higher charging rates from the engine; when temperature deviates from the optimal range, the system modifies engine output and charging parameters to prevent inefficient charging and reduce fuel consumption
2Productivity
If the battery temperature is not managed, then the charging system is simpler, but charging efficiency decreases
Solution Approach 1:
The thermal conditioning system serves multiple functions: it conditions the battery temperature for optimal charging, provides thermal management during operation, and extends battery life through proactive temperature management. This multi-functionality justifies the added system complexity by delivering benefits across multiple operational phases beyond just charging efficiency
Solution Approach 2:
The controller continuously monitors battery temperature and automatically activates the thermal conditioning system when temperature deviations are detected. The system serves itself by using its own resources (engine heat or electrical power) to maintain optimal battery conditions without requiring external intervention, thereby improving charging efficiency through autonomous temperature management
3Power
If engine output is increased to meet accessory power demand, then accessory power availability increases, but fuel consumption increases
Solution Approach 1:
The system maintains continuous engine operation at optimized operating points rather than frequently starting and stopping. By keeping the engine running at efficient operating conditions, the system can meet varying accessory power demands and battery charging requirements without repeatedly entering and exiting efficient operating zones, thereby reducing overall fuel consumption while maintaining power availability
Solution Approach 2:
The controller dynamically adjusts engine output based on real-time conditions including accessory power demands, battery state of charge, and battery temperature. The system flexibly modulates engine power delivery to match actual needs, avoiding excessive fuel consumption by not maintaining constant high output when lower power levels suffice to meet accessory and charging demands
4Reliability
If battery charging is scheduled without thermal conditioning, then the charging process is faster to initiate, but battery temperature may be outside optimal range
Solution Approach 1:
The controller schedules thermal conditioning operations in advance of planned charging events. By proactively bringing the battery temperature into the optimal charging range before charging begins, the system ensures reliable charging conditions are met while minimizing the impact on overall charging timelines through efficient pre-conditioning strategies
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 solution enables faster and more efficient battery charging, reduces fuel consumption, and prolongs battery life by strategically allocating engine output and managing battery temperature, thereby enhancing overall vehicle performance and energy utilization.
Implementation Method 1
a thermal conditioning system for influencing a battery temperature
Implementation Method 2
an electric machine arranged to exchange power with a traction battery
Implementation Method 3
an internal combustion engine (ICE)... operating the ICE to turn the electric machine configured as a generator
Data Source
AI summary
A vehicle includes an electric machine arranged to exchange power with a traction battery. The vehicle also includes a thermal conditioning system for influencing a battery temperature and a controller programmed to schedule battery charging. In response to a temperature of the traction battery exceeding a threshold, the controller issues a command to operate the thermal conditioning system prior to a scheduled battery charge to achieve a predetermined battery temperature at a start of battery charging.