Closed-Loop Feedback Control for Lithium Plating Mitigation
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Solution Overview
Problem
Lithium-ion batteries in electrified vehicles are susceptible to lithium plating, which degrades battery performance and lifespan, particularly under low temperatures and high charging currents, and existing technologies lack effective closed-loop feedback control to mitigate this issue.
Innovation Solution
A closed-loop feedback control system using existing vehicle and battery sensors to manage battery charge rate, regenerative braking, and accessory loads, with a controller updating a battery power vs. temperature table and accumulated plating history to minimize lithium plating, thereby reducing or eliminating plating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high charging currents are applied to the battery, then charging speed and productivity are improved, but lithium plating occurs which degrades battery performance and lifespan
Solution Approach 1:
The patent implements a closed-loop feedback control system that continuously monitors battery state (temperature, charge rate, voltage) and adjusts charging parameters in real-time. The controller receives feedback from battery sensors and dynamically modulates the charging current to maintain optimal charging conditions while preventing lithium plating, thus resolving the contradiction between charging speed and battery lifespan.
Solution Approach 2:
The system dynamically adjusts charging parameters based on real-time battery conditions rather than using fixed charging rates. The controller modifies charge rate, temperature, and voltage parameters adaptively during the charging process, allowing the system to optimize charging speed while preventing plating under varying operating conditions.
2Temperature
If low operating temperature occurs, then battery performance is reduced, but lithium plating is exacerbated under these conditions
Solution Approach 1:
The system changes operating parameters (temperature, charge rate) to prevent lithium plating. When low temperature is detected, the controller adjusts the charge rate parameter and may activate heating elements to raise battery temperature to optimal ranges, thereby eliminating the conditions that cause plating while maintaining battery performance.
Solution Approach 2:
The system takes preliminary action by monitoring temperature and proactively adjusting charging parameters before lithium plating can occur. The controller detects temperature trends and pre-emptively modifies charge rate or activates thermal management to prevent plating conditions from developing.
3Reliability
If additional sensors and hardware are added to detect and control lithium plating, then battery performance and lifespan are improved, but device complexity and cost increase
Solution Approach 1:
The patent makes existing multi-functional sensors serve additional purposes. Standard battery sensors (voltage, current, temperature) that already exist in the vehicle are utilized for plating detection through advanced algorithms, eliminating the need for dedicated plating sensors and reducing system complexity while maintaining reliability.
Solution Approach 2:
The system uses the battery's own existing sensors and operational data to monitor and control plating conditions. The battery management system leverages data already being collected for normal battery operation, performing plating detection as a self-service function without requiring external monitoring hardware.
Data Source
AI summary
A vehicle having a traction battery with at least one cell includes a controller coupled to the traction battery and programmed to modify traction battery current in response to a difference between a lithium plating parameter target value and a lithium plating parameter actual value to reduce the difference. The lithium plating parameter or indicator may be based on a differential open circuit voltage of a battery cell, or a ratio of differential voltage of the at least one cell as a function of time to cell charging rate of the at least one cell.