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NZ784998B2 - External cooling system and method for segmented battery modules mounted within an electric vehicle - Google Patents
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NZ784998B2 - External cooling system and method for segmented battery modules mounted within an electric vehicle - Google Patents

External cooling system and method for segmented battery modules mounted within an electric vehicle Download PDF

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Publication number
NZ784998B2
NZ784998B2 NZ784998A NZ78499822A NZ784998B2 NZ 784998 B2 NZ784998 B2 NZ 784998B2 NZ 784998 A NZ784998 A NZ 784998A NZ 78499822 A NZ78499822 A NZ 78499822A NZ 784998 B2 NZ784998 B2 NZ 784998B2
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NZ
New Zealand
Prior art keywords
energy storage
storage device
coolant
charging
scc
Prior art date
Application number
NZ784998A
Other versions
NZ784998A (en
Inventor
Somphote Ahunai
Charet Akkarabantheongjai
Karun Dansiri
Pun Praphanphoj
Janesak Sudsangtienchai
Wimolmas Wongmakornpan
Original Assignee
Mine Mobility Research Co Ltd
Filing date
Publication date
Application filed by Mine Mobility Research Co Ltd filed Critical Mine Mobility Research Co Ltd
Publication of NZ784998A publication Critical patent/NZ784998A/en
Publication of NZ784998B2 publication Critical patent/NZ784998B2/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L15/00—Methods, circuits, or devices for controlling the traction-motor speed of electrically-propelled vehicles
    • B60L15/20—Methods, circuits, or devices for controlling the traction-motor speed of electrically-propelled vehicles for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2240/00—Control parameters of input or output; Target parameters
    • B60L2240/10—Vehicle control parameters
    • B60L2240/36—Temperature of vehicle components or parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2240/00—Control parameters of input or output; Target parameters
    • B60L2240/40—Drive Train control parameters
    • B60L2240/54—Drive Train control parameters related to batteries
    • B60L2240/545—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/14—Conductive energy transfer
    • B60L53/16—Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/30—Constructional details of charging stations
    • B60L53/302—Cooling of charging equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/30—Constructional details of charging stations
    • B60L53/305—Communication interfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/60—Monitoring or controlling charging stations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/60—Monitoring or controlling charging stations
    • B60L53/66—Data transfer between charging stations and vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
    • B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
    • B60L58/18—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries of two or more battery modules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
    • B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
    • B60L58/24—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries for controlling the temperature of batteries
    • B60L58/26—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries for controlling the temperature of batteries by cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2200/00—Type of vehicle
    • B60Y2200/90—Vehicles comprising electric prime movers
    • B60Y2200/91—Electric vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2306/00—Other features of vehicle sub-units
    • B60Y2306/05—Cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2400/00—Special features of vehicle units
    • B60Y2400/11—Electric energy storages
    • B60Y2400/112—Batteries
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2400/00—Special features of vehicle units
    • B60Y2400/30—Sensors
    • B60Y2400/302—Temperature sensors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/482—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for several batteries or cells simultaneously or sequentially
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/486—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for measuring temperature
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/61—Types of temperature control
    • H01M10/613—Cooling or keeping cold
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/62—Heating or cooling; Temperature control specially adapted for specific applications
    • H01M10/625—Vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/63—Control systems
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/656—Means for temperature control structurally associated with the cells characterised by the type of heat-exchange fluid
    • H01M10/6567—Liquids
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/656—Means for temperature control structurally associated with the cells characterised by the type of heat-exchange fluid
    • H01M10/6567—Liquids
    • H01M10/6568—Liquids characterised by flow circuits, e.g. loops, located externally to the cells or cell casings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/66—Heat-exchange relationships between the cells and other systems, e.g. central heating systems or fuel cells
    • H01M10/667—Heat-exchange relationships between the cells and other systems, e.g. central heating systems or fuel cells the system being an electronic component, e.g. a CPU, an inverter or a capacitor
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H01M2010/4271—Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H01M2010/4278—Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/70—Energy storage systems for electromobility, e.g. batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10—Technologies relating to charging of electric vehicles
    • Y02T90/14—Plug-in electric vehicles

Abstract

system or method for individualized coolant flow to each of a plurality of energy storage devices 10 housed in an electric vehicle. Each energy storage device 10 includes a heat exchanger 11 coupled in thermal conductivity with a segmented battery module 13. The segmented battery module 13 includes battery cells 13B and sensors (13C, 13D, and 13E). The heat exchanger 11 includes an HE flow controller 11C. Individual sensor information for each energy storage device 10 is collected via the BMU 13A of each segmented battery module 13. The charging SCC 22 uses this individual sensor information to calculate the HE flow rate of coolant pumped through each energy storage device’s 10 heat exchanger 11 to cool the battery cells 13B of the energy storage device 10. Coolant delivered to the heat exchangers 11 is cooled by an external cooling unit 21 of a power source 20 during each charging session.

Claims (18)

1.[Claim 1] A cooling system for individualized cooling of a plurality of segmented battery modules of an electric vehicle by way of a first coolant and a second coolant that flow 5 in distinct first and second coolant pathways, respectively, the system comprising: a plurality of energy storage devices housed in the electric vehicle, each energy storage device comprising: a heat exchanger (HE) having a HE inlet and a HE outlet; a HE flow controller comprising a variable speed drive (VSD) coolant pump; and one of the segmented battery modules in thermal communication with the heat exchanger, wherein the 10 segmented battery module of each energy storage device comprises: a plurality of battery cells; and a battery management unit (BMU) in data communication with a plurality of sensors, the sensors including at least one temperature sensor located within the segmented battery module, wherein the BMU is configured to collect sensor information from the sensors; 15 an internal cooling unit (ICU) housed in the electric vehicle and configured to generate a cold first coolant from a warm first coolant, the internal cooling unit having an ICU inlet for receiving the warm first coolant and an ICU outlet for providing the cold first coolant; a pair of coolant trunks housed in the electric vehicle and comprising a warm trunk configured to receive the warm first coolant from the HE outlet of each energy storage device 20 and provide the warm first coolant to the ICU inlet; and a cool trunk configured to receive the cold first coolant from the ICU outlet and provide the cold first coolant to the HE inlet of each energy storage device, wherein the heat exchanger of each energy storage device, the pair of coolant trunks, the internal cooling unit, the ICU outlet, and the ICU inlet form the first coolant pathway as a segmented coolant pathway in which for each energy storage 25 device a HE flow rate for the energy storage device is regulated through the HE flow controller of the energy storage device; an external cooling unit disposed external to the electric vehicle and providing the second coolant, the external cooling unit including an ECU inlet configured to receive a warm second coolant, and an ECU outlet configured to provide a cold second coolant, wherein the 30 external cooling unit, the ECU inlet, and the ECU outlet form the second coolant pathway; an external-to-internal heat exchanger interfacing between the segmented coolant pathway and the second coolant pathway, wherein the external cooling unit is configured to provide additional cooling to the cold first coolant through a heat exchange between the cold first coolant and the cold second coolant using the external-to-internal heat exchanger prior to ICU outlet provision of the cold first coolant to the cool trunk, and is configured to receive the warm second coolant from the 5 external-to-internal heat exchanger; a master battery management system (MBMS) housed in the electric vehicle, wherein the MBMS is in wired or wireless data communication with the BMU of each energy storage device; a power source disposed external to the electric vehicle, the power source electrically 10 coupled to the plurality of energy storage devices of the electric vehicle and configured to charge the plurality of energy storage devices during a charging session, wherein the external cooling unit is housed in the power source; a charging segmented cooling controller (SCC), the charging SCC including a set of parameters, 15 wherein during each charging session the charging SCC is in direct or indirect data communication by wire or wirelessly with: the external cooling unit; the HE flow controller of each energy storage device; the MBMS; and 20 the BMU of the segmented battery module of each energy storage device via the MBMS; wherein during each charging session the charging SCC is configured to directly or indirectly receive the sensor information collected by the BMU of each energy storage device wirelessly or by wire, the sensor information including at least temperature information 25 measured by the at least one temperature sensor located within the segmented battery module of the energy storage device; wherein the set of parameters includes at least a preferred temperature range for the segmented battery module of each energy storage device; wherein during each charging session the charging SCC is configured to periodically: 30 calculate or recalculate an optimal range for the HE flow rate of the heat exchanger of each energy storage device, the optimal range a function of: (a) the sensor information received by the charging SCC from the sensors of the energy storage device via the BMU of the energy storage device; and (b) the preferred temperature range for the energy storage device; and control by wire or wirelessly the HE flow rate of each energy storage device, via the direct or indirect data communication with the HE flow controller of the energy storage device, to maintain the HE flow rate within the optimal range; 5 wherein the charging SCC is housed in the power source and, for each energy storage device, data communication between the charging SCC and the HE flow controller of the energy storage device does not pass through either: the MBMS of the electric vehicle; or the BMU of the energy storage device; and 10 wherein during each charging session the charging SCC is configured to prioritize individual cooling needs of the segmented battery modules by increasing or decreasing the flow of the first coolant through the HE flow controller of each energy storage device to establish an individualized flow of the first coolant to each energy storage device. 15 [
2.Claim 2] The system of claim 1, wherein during each charging session the charging SCC is configured to directly control the HE flow controller of each energy storage device of the electric vehicle.
3.[Claim 3] The system of claim 1 or 2, wherein the system further comprises a control 20 loop, and wherein during each charging session the charging SCC employs the control loop to adjust a power rating delivered to the external cooling unit, prioritize delivery of the cold first coolant to at least one of the energy storage devices according to the sensor information of the segmented battery module of each of the energy storage devices, and adjust the HE flow rate of the cold first coolant through one or more of the HE flow controllers.
4.[Claim 4] The system of any one of the preceding claims, wherein the set of parameters includes a thermal model for each energy storage device and a preferred temperature range for each energy storage device, and wherein the charging SCC calculates for each energy storage device (i) an estimated heat generation for the energy storage device using the 30 thermal model, as well as the preferred temperature range, and current information of the sensor information of the energy storage device; and (ii) the optimal range of the HE flow rate of the energy storage device to counteract the estimated heat generation by the energy storage device.
5.[Claim 5] The system of any one of the preceding claims, wherein the coolant is a fluid, water, a gas, or air. 5 [
6.Claim 6] The system of any one of the preceding claims, wherein the heat exchanger and the segmented battery module of each energy storage device are paired in thermal conductivity via a thermal interface, the heat exchanger for each energy storage device includes a heat sink conforming to at least one outer surface area of the segmented battery module of the energy storage device, and 10 the thermal interface between the heat sink and the segmented battery module of each energy storage device is a compressible thermally conductive material or a thermally conductive paste.
7.[Claim 7] The system of claim 6, wherein the heat sink of each energy storage device 15 comprises an aluminium shell enclosing the HE passages of the energy storage device.
8.[Claim 8] The system of any one of the preceding claims, wherein the electric vehicle comprises a locomotive including a vehicle control system and at least one traction motor, and 20 operation of the at least one traction motor is controlled by the vehicle control system.
9.[Claim 9] The system of any one of the preceding claims, wherein the electric vehicle is a power car corresponding to a locomotive, and which includes one or more power outlets electrically couplable to one or more power inlets of the 25 locomotive.
10.[Claim 10] A method for individualized cooling of a plurality of segmented battery modules of an electric vehicle by way of a first coolant and a second coolant that flow in distinct first and second coolant pathways, respectively, the method comprising: 30 maintaining a plurality of energy storage devices housed in the electric vehicle, each energy storage device comprising: a heat exchanger (HE) having a HE inlet and a HE outlet; a HE flow controller comprising a Variable Speed Drive (VSD) coolant pump; and one of the segmented battery modules in thermal communication with the heat exchanger, wherein the segmented battery module of each energy storage device comprises: a plurality of battery cells; and a battery management unit (BMU) in data communication with a plurality of sensors, the sensors including at least one temperature sensor located within the segmented battery module, wherein the BMU is configured to collect sensor information from the 5 sensors; maintaining an internal cooling unit configured to generate a cold first coolant from a warm first coolant, the internal cooling unit having an ICU inlet for receiving the warm first coolant and an ICU outlet for providing the cold first coolant; maintaining a pair of coolant trunks housed in the electric vehicle and comprising a 10 warm trunk configured to receive the warm first coolant from each HE outlet and provide the warm first coolant to the ICU inlet; and a cool trunk configured to receive the cold first coolant from the ICU outlet and provide the cold first coolant to each HE inlet, wherein the heat exchanger of each energy storage device, the pair of coolant trunks, the internal cooling unit, the ICU outlet, and the ICU inlet form the first coolant pathway as a segmented coolant 15 pathway in which for each energy storage device a HE flow rate for the energy storage device is regulated through the HE flow controller of the energy storage device; maintaining an external cooling unit disposed external to the electric vehicle and providing the second coolant, the external cooling unit including an ECU inlet configured to receive a warm second coolant, and an ECU outlet configured to provide a cold second coolant, 20 wherein the external cooling unit, the ECU inlet, and the ECU outlet form the second coolant pathway; maintaining an external-to-internal heat exchanger interfacing between the segmented coolant pathway and the second coolant pathway; establishing communication between a master battery management system (MBMS) housed 25 in the electric vehicle and the BMU of each energy storage device configured to collect the sensor information; maintaining a power source disposed external to the electric vehicle, the power source electrically coupled to the plurality of energy storage devices of the electric vehicle and configured to charge the plurality of energy storage devices during a charging session, 30 wherein the external cooling unit is housed in the power source; providing, during the charging session, additional cooling to the cold first coolant from the cold second coolant through a heat exchange between the cold first coolant and the cold second coolant using the external-to-internal heat exchanger prior to ICU outlet provision of the cold first coolant to the cool trunk; and receiving, during the charging session, a warm second coolant from the external-to-internal heat exchanger into the external cooling unit through the ECU inlet during the charging 5 session; maintaining a charging segmented cooling controller (SCC), the charging SCC including a set of parameters, wherein during each charging session the charging SCC is in direct or indirect data 10 communication by wire or wirelessly with: the external cooling unit; the HE flow controller of each energy storage device; the MBMS; and the BMU of the segmented battery module of each energy storage device via the 15 MBMS; wherein during each charging session the charging SCC is configured to directly or indirectly receive the sensor information collected by the BMU of each energy storage device wirelessly or by wire, the sensor information including at least temperature information measured by the at least one temperature sensor located within the segmented battery module 20 of the energy storage device; wherein the set of parameters includes at least a preferred temperature range for the segmented battery module of each energy storage device; wherein the charging SCC is maintained in the power source and, for each energy storage device, data communication between the charging SCC and the HE flow controller of 25 the energy storage device does not pass through either: the MBMS of the electric vehicle; or the BMU of the energy storage device; commencing the charging session for the plurality of energy storage devices; during the charging session, periodically employing the charging SCC to calculate or 30 recalculate an optimal range for the HE flow rate of the heat exchanger of each energy storage device, the optimal range a function of: (a) the sensor information received by the charging SCC from the sensors of the energy storage device via the BMU of the energy storage device; and (b) the preferred temperature range for the energy storage device; and during the charging session, controlling by wire or wirelessly the HE flow rate of each energy storage device, via the direct or indirect data communication with the HE flow controller of the energy storage device, to maintain the HE flow rate within the optimal 5 range, such that the SCC prioritizes individual cooling needs of the segmented battery modules by way of increasing or decreasing flow of the first coolant through the HE flow controller of each energy storage device to establish an individualized flow of the first coolant to each energy storage device.
11.[Claim 11] The method of claim 10, wherein during each charging session the charging
12.SCC directly controls the HE flow controller of the energy storage device of the electric vehicle. 15 [Claim 12] The method of claim 10 or 11, further comprising maintaining a control loop during each charging session, wherein during each charging session the charging SCC employs the control loop to: adjust a power rating delivered to the external cooling unit, prioritize delivery of the cold first coolant to at least one of the energy storage devices 20 according to a temperature indicated by the temperature sensor of the segmented battery module of each of the energy storage devices, and adjust the HE flow rate of coolant through one or more of the HE flow controllers through the control loop. 25 [
13.Claim 13] The method of any one of claims 10 to 12, further comprising calculating by way of the SCC, for each energy storage device, (i) an estimated heat generation for the energy storage device using: a thermal model of the energy storage device from the set of parameters, a preferred temperature range for the energy storage device and current sensor information of the energy storage device, and (ii) an optimal range of the HE flow rate of the 30 energy storage device to counteract the estimated heat generation of the energy storage device.
14.[Claim 14] The method of any one of claims 10 to 13, wherein the coolant is a fluid, water, a gas, or air.
15.[Claim 15] The method of any one of claims 10 to 14, 5 wherein the heat exchanger and the segmented battery module of each energy storage device are paired in thermal conductivity via a thermal interface; the heat exchanger for each energy storage device includes a heat sink conforming to at least one outer surface area of the segmented battery module of the energy storage device; and the thermal interface between the heat sink and the segmented battery module of each energy 10 storage device is a compressible thermally conductive material or a thermally conductive paste.
16.[Claim 16] The method of claim 15, wherein the heat sink of each energy storage device comprises an aluminium shell enclosing the HE passages of the energy storage device.
17.[Claim 17] The method of any one of claims 10 to 16, wherein the electric vehicle comprises a locomotive including a vehicle control system and at least one traction motor, and operation of the at least one traction motor is controlled by the vehicle control system.
18.[Claim 18] The method of any one of claims 10 to 17, wherein the electric vehicle is a power car corresponding to a locomotive, and which provides one or more power outlets, and the one or more power outlets are electrically couplable to one or more power inlets of the 25 locomotive.
NZ784998A 2022-02-10 External cooling system and method for segmented battery modules mounted within an electric vehicle NZ784998B2 (en)

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NZ784998B2 true NZ784998B2 (en) 2024-05-24

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