Modular Battery Cooling Control for Variable Thermal Loads
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Solution Overview
Problem
Electric machines with batteries face challenges in maintaining optimal operating temperatures due to variable thermal output during different operating conditions, leading to reduced battery lifetimes and potential failures, especially since existing thermal management systems do not provide controlled variable cooling.
Innovation Solution
A modular battery thermal management system (BTMS) with independently operable units and a controller that adjusts cooling based on temperature levels, actively operating specific units to maintain battery temperatures within a desired range, ensuring efficient and dynamic cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermal management system cools the battery at all times, then the battery temperature is maintained within operating range, but energy is wasted when cooling is not needed
Solution Approach 1:
The system dynamically adjusts cooling based on real-time battery temperature and state of charge. The controller activates cooling only when temperature exceeds threshold or during charging operations, rather than continuous operation, optimizing energy usage while maintaining reliability
Solution Approach 2:
The system uses temperature sensors and controller feedback to monitor battery conditions and adjust cooling activation accordingly. Cooling is activated or deactivated based on feedback from temperature measurements and charging state, preventing unnecessary energy consumption while ensuring temperature control when needed
2Reliability
If the thermal management system provides high level cooling, then battery temperature is controlled during high charge draw, but the system complexity increases
Solution Approach 1:
The thermal management system is divided into modular components including temperature sensors, controllers, and cooling mechanisms that can be independently activated. This segmentation allows the system to provide high-level cooling only when and where needed, maintaining reliability during high charge draw while avoiding unnecessary complexity in system architecture
3Reliability
If the battery is cooled during charging, then temperature control is maintained, but additional energy consumption occurs
Solution Approach 1:
The controller monitors battery temperature and state of charge in real-time, activating cooling during charging only when temperature thresholds are exceeded. This feedback-based control ensures temperature management during charging while minimizing unnecessary energy consumption when cooling is not required
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
The BTMS effectively prolongs battery longevity, reduces the risk of failure, and optimizes operating conditions by providing variable and controlled cooling levels, addressing the limitations of existing systems.
Implementation Method 1
Batteries of electric machines generally have a thermal operating range that is tighter than other components of the electric machine
Implementation Method 2
The BTMS includes a first BTMS unit, a second BTMS unit, wherein the first BTMS unit and the second BTMS unit are independently operable
Data Source
AI summary
A modular and on-demand battery thermal management system (BTMS) for an electric machine with a battery is disclosed. The BTMS may include one or more independently operable BTMS modules, where each BTMS module may be configured to cool a corresponding component of the electric machine, such as a particular battery pack. Each BTMS module, in turn, may include a plurality of BTMS units that cool coolant that is to be delivered to the components that are to be cooled within the electric machine. The individual BTMS units may be independently operable by a BTMS controller based at least in part on the cooling needs of the components to be cooled. The BTMS controller is also configured to select BTMS units to operate in a manner that maximizes the operating life and durability of the BTMS.