Intelligent temperature control system for extending battery pack life

• US 8,117,857 B2
• Filed: 02/20/2009
• Issued: 02/21/2012
• Est. Priority Date: 02/20/2009
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Kelty, Kurt Russell, Kohn, Scott Ira, Hermann, Weston Arthur, Kishiyama, Clay Hajime
• Primary Examiner(s): Jiang, Chen Wen
• Application Number:
  US12/378,909
• Publication Number:
  US 20100212339A1
• Time in Patent Office: 1,096 Days
• Field of Search: 621/29, 622/39, 622/44, 622/592, 622/386, 320/150, 320/137, 180/68.4, 219/209, 700/299
• US Class Current: 62/129
• CPC Class Codes: B60H 2001/00307 Component temperature regulation using a liquid flow
• CPC Class Codes: B60L 2260/56 Temperature prediction, e.g. for pre-cooling
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 58/13 Maintaining the SoC within a determined range
• CPC Class Codes: B60L 58/16 responding to battery ageing, e.g. to the number of charging cycles or the state of health [SoH]
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B60L 58/27 by heating
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/615 Heating or keeping warm
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/633 characterised by algorithms, flow charts, software details or the like
• CPC Class Codes: H01M 10/6568 characterised by flow circuits, e.g. loops, located externally to the cells or cell casings
• CPC Class Codes: H01M 10/6571 Resistive heaters arrangements for heating the battery by its resistance to the internal current H01M10/637
• CPC Class Codes: H01M 10/663 the system being an air-conditioner or an engine
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A method and apparatus for actively cooling the battery pack of an electric vehicle after the vehicle has been turned off, thereby limiting the adverse effects of temperature on battery life, are provided. Different battery pack cooling techniques are provided, thus allowing the cooling technique used in a particular instance to be selected not only based on the thermal needs of the battery pack, but also on the thermal capacity and energy requirements of the selected approach.

Claims

1. A thermal management system for an electric vehicle comprising:

an electrical energy storage system (ESS) coupled to an electric vehicle powertrain, said electrical ESS supplying power to an electric motor of said electric vehicle powertrain;

a cooling system comprised of a coolant within a coolant loop, said coolant loop in thermal communication with said ESS, said coolant system further comprised of a coolant pump for pumping said coolant through said coolant loop;

a refrigeration system independent of said cooling system;

a heat exchanger in thermal communication with said refrigeration system and in thermal communication with said cooling system via said coolant loop;

a temperature control system coupled to said cooling system, wherein said cooling system is under the control of said temperature control system, wherein said temperature control system further comprises;

a vehicle condition monitor, wherein said vehicle condition monitor outputs a first condition signal when said electric vehicle is on and outputs a second condition signal when said electric vehicle is off;

a charging system monitor, wherein said charging system monitor outputs a first status signal when said electric vehicle is coupled to a battery charging system and outputs a second status signal when said electric vehicle is not coupled to a battery charging system;

at least one temperature sensor in thermal communication with said ESS, said at least one temperature sensor monitoring an ESS temperature;

a comparator circuit for comparing said ESS temperature with a preset temperature, wherein said comparator circuit outputs a first signal when said ESS temperature is less than said preset temperature and outputs a second signal when said ESS temperature is greater than said preset temperature; and

a cooling system controller coupled to said cooling system, said cooling system controller configured to output a control signal to said cooling system when said vehicle condition monitor outputs said second condition signal and said charging system monitor outputs said second status signal, said cooling system controller further configured to receive said first and second signals from said comparator circuit, wherein said control signal activates said coolant pump when said cooling system controller receives said second signal, and wherein said control signal deactivates said coolant pump when said cooling system controller receives said first signal, and wherein said control signal output by said cooling system controller activates said refrigeration system when said cooling system controller receives said second signal from said comparator circuit.

2. The thermal management system of claim 1, said cooling system further comprising a radiator coupled to said coolant loop, wherein said coolant passes through said radiator as said coolant is pumped through said coolant loop with said coolant pump.

3. The thermal management system of claim 1,

wherein said preset temperature is comprised of a range of temperatures, wherein said comparator circuit outputs a third signal when said ESS temperature is within said range of temperatures, wherein said control signal output by said cooling system controller activates said coolant pump when said cooling system controller receives said third signal.

4. The thermal management system of claim 1, cooling system further comprising a blower fan for directing air through said radiator, wherein said control signal output by said cooling system controller activates said blower fan when said cooling system controller receives said second signal from said comparator circuit.

5. The thermal management system of claim 1, further comprising a state of charge (SOC) sensor coupled to said ESS and to said temperature control system, said SOC sensor monitoring a current SOC of said ESS, wherein said cooling system controller is configured to output a deactivation signal to said cooling system when said current SOC is less than a preset target SOC.

6. A thermal management system for an electric vehicle, comprising:

an electrical energy storage system (ESS) coupled to an electric vehicle powertrain, said electrical ESS supplying power to an electric motor of said electric vehicle powertrain;

a cooling system comprised of a coolant within a coolant loop, said coolant loop in thermal communication with said ESS, said coolant system further comprised of a coolant pump for pumping said coolant through said coolant loop, said cooling system further comprising;

a radiator coupled to said coolant loop, wherein said coolant passes through said radiator as said coolant is pumped through said coolant loop with said coolant pump;

a blower fan for directing air through said radiator;

a temperature control system coupled to said cooling system, wherein said cooling system is under the control of said temperature control system, wherein said temperature control system further comprises;

a vehicle condition monitor, wherein said vehicle condition monitor outputs a first condition signal when said electric vehicle is on and outputs a second condition signal when said electric vehicle is off;

a charging system monitor, wherein said charging system monitor outputs a first status signal when said electric vehicle is coupled to a battery charging system and outputs a second status signal when said electric vehicle is not coupled to a battery charging system;

at least one temperature sensor in thermal communication with said ESS, said at least one temperature sensor monitoring an ESS temperature;

a comparator circuit for comparing said ESS temperature with a preset temperature, wherein said comparator circuit outputs a first signal when said ESS temperature is less than said preset temperature and outputs a second signal when said ESS temperature is greater than said preset temperature;

a cooling system controller coupled to said cooling system, said cooling system controller configured to output a control signal to said cooling system when said vehicle condition monitor outputs said second condition signal and said charging system monitor outputs said second status signal, said cooling system controller further configured to receive said first and second signals from said comparator circuit, wherein said control signal activates said coolant pump when said cooling system controller receives said second signal, and wherein said control signal deactivates said coolant pump when said cooling system controller receives said first signal;

wherein said control signal output by said cooling system controller activates said blower fan when said cooling system controller receives said second signal from said comparator circuit; and

wherein said preset temperature is comprised of a range of temperatures, wherein said comparator circuit outputs a third signal when said ESS temperature is within said range of temperatures, wherein said control signal output by said cooling system controller activates said coolant pump when said cooling system controller receives said third signal.

7. The thermal management system of claim 6, further comprising a state of charge (SOC) sensor coupled to said ESS and to said temperature control system, said SOC sensor monitoring a current SOC of said ESS, wherein said cooling system controller is configured to output a deactivation signal to said cooling system when said current SOC is less than a preset target SOC.

8. A thermal management system for an electric vehicle comprising:

an electrical energy storage system (ESS) coupled to an electric vehicle powertrain, said electrical ESS supplying power to an electric motor of said electric vehicle powertrain;

a cooling system comprised of a coolant within a coolant loop, said coolant loop in thermal communication with said ESS, said coolant system further comprised of a coolant pump for pumping said coolant through said coolant loop, said coolant system further comprised of a radiator coupled to said coolant loop, wherein said coolant passes through said radiator as said coolant is pumped through said coolant loop with said coolant pump;

a refrigeration system independent of said cooling system, said refrigeration system comprised of a compressor and a condenser;

a heat exchanger in thermal communication with said refrigeration system and in thermal communication with said cooling system via said coolant loop;

a cooling system controller coupled to said cooling system and to said refrigeration system, said cooling system controller activated when said electric vehicle is turned off, said cooling system controller configured to output a cooling system deactivation signal to said cooling system and a refrigeration system deactivation signal to said refrigeration system in response to receiving a first command signal, said cooling system controller configured to output a cooling system activation signal to said cooling system and said refrigeration system deactivation signal to said refrigeration system in response to receiving a second command signal, and said cooling system controller configured to output said cooling system activation signal to said cooling system and a refrigeration system activation signal to said refrigeration system in response to receiving a third command signal;

a state of charge (SOC) sensor coupled to said ESS and monitoring a current SOC of said ESS, wherein said SOC sensor transmits a first command signal to said cooling system controller when said current SOC is less than a preset target SOC;

at least one temperature sensor in thermal communication with said ESS, said at least one temperature sensor monitoring a current ESS temperature; and

a comparator circuit for comparing said current ESS temperature with a preset temperature range, wherein said comparator circuit outputs said first command signal to said cooling system controller when said current ESS temperature is lower than said preset temperature range, wherein said comparator circuit outputs said second command signal to said cooling system controller when said current ESS temperature is within said preset temperature range, and wherein said comparator circuit outputs said third command signal to said cooling system controller when said current ESS temperature is greater than said preset temperature range.