Predictive Battery Charging Control for Thermal Cycling Reduction

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Solution Overview

Problem

Conventional battery thermal management strategies that rely on on/off thermal control to maintain battery temperature below a threshold reduce battery lifespan and increase charging time due to repeated cycling, leading to inefficient battery operation.

Innovation Solution

A predictive physics-based model is used to forecast future battery temperatures and adjust charging profiles proactively, optimizing power distribution between charging, heating, and cooling to maintain the battery within a temperature window, minimizing lithium plating and over-drain, and using a cost function to optimize power usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If on/off thermal management strategy is used to maintain battery temperature below threshold, then battery temperature control is achieved, but battery lifespan decreases and charging time increases

Engineering Contradiction:

Improvebattery temperature controlVSAvoidbattery lifespan

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The system performs preliminary thermal management actions by predicting future battery temperature using a physics-based model and adjusting charging power before temperature thresholds are reached. This proactive approach prevents the need for repeated on/off thermal cycling, thereby extending battery lifespan while maintaining effective temperature control.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention transitions from static on/off thermal control to dynamic predictive control. The system continuously adjusts charging power based on real-time battery state monitoring and future temperature predictions, creating a smooth, adaptive charging profile that eliminates frequent cycling and reduces thermal stress on the battery.

Inventive Principle:

Principle #15Dynamics

2Temperature

If on/off thermal management strategy is used to maintain battery temperature below threshold, then battery temperature control is achieved, but charging time increases

Engineering Contradiction:

Improvebattery temperature controlVSAvoidcharging time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The system performs preliminary thermal management actions by predicting future battery temperature using a physics-based model and adjusting charging power before temperature thresholds are reached. This proactive approach prevents thermal excursions that would require charging interruptions, thereby reducing overall charging time while maintaining effective temperature control.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #15Dynamics

3Reliability

If predictive physics model with cost function is used to optimize charging profile, then battery lifespan is extended and charging efficiency improves, but system complexity increases

Engineering Contradiction:

Improvebattery lifespanVSAvoidcontrol system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system implements feedback control by continuously monitoring battery state (temperature, charge level, current) and using this information to update the physics-based model predictions. The cost function processes this feedback to determine optimal charging power adjustments, creating a closed-loop control system that extends battery lifespan through adaptive, data-driven decision-making.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The invention replaces complex mechanical thermal management systems with a software-based predictive control approach. Instead of relying on physical thermal control mechanisms, the system uses a physics-based mathematical model and cost function optimization to manage battery temperature and charging, reducing mechanical complexity while improving control precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12409750B2Predictive control for proactive thermal and energy management charging

Publication Date: 2025.09.09 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A method for controlling a vehicle charging and thermal operation includes monitoring at least a charge characteristic of a battery system and a thermal characteristic of the battery system. The method predicts a battery system temperature at a future time (t) based at least in part on the monitored characteristics using a predictive physics model and maintains the battery system temperature above a minimum temperature threshold and below a maximum temperature threshold by adjusting a charging profile based at least in part on the predicted battery system temperature.