Modular EV Battery Cooling with Replaceable Energy Modules
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Solution Overview
Problem
Current energy systems in electric vehicles lack efficient cooling mechanisms and the ability to dynamically manage energy sources, leading to suboptimal performance, reduced battery life, and limited charging flexibility, as well as inadequate control over motor noise and torque distribution.
Innovation Solution
A modular energy system with a cooling enclosure that routes coolant to components based on temperature needs and a configuration allowing for rapid replacement of energy sources, enabling optimized thermal management and dynamic energy distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional battery pack design is used, then the system structure is simple, but thermal management is difficult and battery life is limited
Solution Approach 1:
The patent divides the battery pack into modular units with individual cooling channels for each battery module. This segmentation allows independent thermal management of each module, enabling precise temperature control without requiring a completely complex system architecture. Each module has its own cooling flow path, which can be controlled independently based on thermal needs.
Solution Approach 2:
The cooling system is designed with varying cooling capacities directed at different battery modules based on their specific thermal conditions. The system can adjust coolant flow distribution to provide enhanced cooling to modules that require it while maintaining adequate cooling elsewhere, achieving localized thermal optimization without uniform system complexity.
2Reliability
If the entire battery pack is replaced upon cell failure, then system reliability is improved, but loss of time and increased cost occur
Solution Approach 1:
The battery pack is designed as a modular system where individual cells or small groups of cells can be independently accessed and replaced. This segmentation enables targeted replacement of only the failed components rather than the entire pack, significantly reducing replacement time and cost while maintaining system reliability through continuous operation of functional modules.
Solution Approach 2:
The system includes a management system that monitors individual cell conditions and can identify failing cells before they cause complete pack failure. This preliminary detection allows for planned, minimal-disruption replacement of specific cells, reducing unexpected downtime and maintaining higher overall reliability.
3Adaptability or versatility
If conventional charging systems are used, then system complexity is low, but charging flexibility and optimization capability are limited
Solution Approach 1:
The charging system is designed to dynamically adjust charging parameters for individual battery modules based on real-time monitoring of cell conditions, temperature, and state of charge. This dynamic control enables flexible charging strategies such as pulsed charging, variable current rates, and module-specific charging schedules, achieving high adaptability through intelligent control rather than hardware complexity.
Solution Approach 2:
The system incorporates continuous monitoring of individual cell parameters and uses this feedback to automatically adjust charging currents and voltages for each module. This feedback mechanism enables optimized charging that adapts to changing battery conditions, improving charging flexibility and efficiency without requiring complex manual intervention or predetermined charging schedules.
4Productivity
If the weakest cell constrains the entire battery pack, then system simplicity is maintained, but productivity and performance are reduced
Solution Approach 1:
The battery management system is segmented to independently monitor and control each battery module. This segmentation allows the system to identify and manage the performance of individual cells or modules separately, enabling the strongest modules to operate at full capacity while the weakest module receives adjusted parameters, thereby maximizing overall pack productivity without requiring complete system uniformity.
Solution Approach 2:
The control system applies different operating parameters to different battery modules based on their individual performance characteristics. Modules with higher capability can deliver higher currents and operate at higher voltages, while weaker modules receive adjusted parameters within their safe operating limits. This local optimization approach maximizes the aggregate performance of the entire battery pack without being constrained by the weakest link.
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
Improves the performance and longevity of energy systems by ensuring optimal temperature regulation and allowing for efficient energy source management, enhancing overall vehicle efficiency and charging capabilities.
Implementation Method 1
an enclosure surrounding the modular energy system to route the coolant in a manner that passes in proximity with components of modules of the modular energy system
Implementation Method 2
The embodiments can provide for a sequence of pumping coolant such that the coolant cools components of the electric vehicle having the lowest desired operating temperature first, followed by the components having relatively higher desired operating temperatures
Data Source
AI summary
Example embodiments of systems, devices, and methods are provided herein for cooling a modular energy system. The embodiments can utilize an enclosure surrounding the modular energy system to route the coolant in a manner that passes in proximity with components of modules of the modular energy system. The embodiments can provide for a sequence of pumping coolant such that the coolant cools components of the electric vehicle having the lowest desired operating temperature first, followed by the components having relatively higher desired operating temperatures. Example embodiments of systems, devices, and methods are also provided herein for a modular energy system with removable and replaceable energy sources. The system can be positioned within an electric vehicle in a manner that permits rapid removal of energy sources having a relatively low state of charge and replacement of those energy sources with different energy sources having a relatively higher state of charge.