Modular Battery Thermal Management for Variable Cooling Demand
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Solution Overview
Problem
Electric machinery powered by batteries faces challenges in maintaining optimal battery temperatures due to variable thermal output during different operating conditions, leading to reduced battery lifetimes and potential failure, which can result in significant costs and downtime in construction, mining, and other activities.
Innovation Solution
A modular battery thermal management system (BTMS) with independently operable units that adjust cooling levels based on real-time temperature data from the battery, using a controller to activate or passivate BTMS units within each module to maintain the battery within a desired temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a battery thermal management system provides continuous cooling capacity, then the battery can be cooled under high thermal output conditions, but the system complexity and energy consumption increase when full cooling capacity is not needed
Solution Approach 1:
The thermal management system is divided into multiple independent cooling modules, each capable of being individually activated or deactivated. This segmentation allows the system to provide variable cooling capacity by engaging only the necessary number of modules based on real-time thermal demands, thereby reducing overall system complexity and energy consumption during low-heat conditions while maintaining adequate cooling capacity during high-heat conditions.
2Adaptability or versatility
If the thermal management system uses fixed cooling capacity, then the system design is simpler, but it cannot adapt to variable thermal output during different operating conditions
Solution Approach 1:
The thermal management system employs dynamic control of cooling module activation based on real-time monitoring of battery thermal output. The system can adapt its cooling capacity by selectively engaging or disengaging cooling modules in response to varying operational conditions, such as charging rates, discharging rates, and ambient temperatures, thereby achieving versatility without requiring complete redesign for each scenario.
3Reliability
If multiple cooling modules are always active, then adequate cooling is provided under all conditions, but energy consumption increases during low thermal output operations
Solution Approach 1:
The thermal management system incorporates feedback control mechanisms that continuously monitor battery temperature and thermal output, then adjust the activation state of cooling modules accordingly. When thermal output is low, the feedback signal deactivates unnecessary cooling modules, reducing energy consumption. When thermal output increases, the feedback signal activates the required number of modules to maintain adequate cooling, thus balancing reliability with energy efficiency.
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 regulates battery temperatures, enhancing longevity and reducing the risk of failure by providing dynamic and variable cooling levels, thus minimizing downtime and operational costs in electric machinery.
Implementation Method 1
a coolant line configured to circulate coolant to cool the battery
Implementation Method 2
a first BTMS unit and a second BTMS unit, wherein the first BTMS module is configured to provide coolant cooled by the first BTMS unit and the second BTMS unit
Data Source
AI summary
A modular and on-demand battery thermal management system (BTMS) for an electric machine or a stationary energy storage solution 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 control pumps and valves to appropriately direct coolant to the BTMS units that are operating in a modular fashion.