Method of controlling system temperature to extend battery pack life

• US 8,899,492 B2
• Filed: 10/03/2011
• Issued: 12/02/2014
• 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): NORMAN, MARC E
• Application Number:
  US13/251,307
• Publication Number:
  US 20120021258A1
• Time in Patent Office: 1,156 Days
• Field of Search: 622/39, 622/592, 236/34, 320/137, 320/150, 429/50
• US Class Current: 236/34
• 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 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, is 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 method of controlling the temperature of an electrical energy storage system (ESS) coupled to an electric powertrain of an electric vehicle, the method comprising the steps of:

a) monitoring an operational condition of said electric vehicle, wherein said operational condition is either in a first state of operation or a second state of operation, wherein said first state of operation corresponds to said electric vehicle being turned on, and wherein said second state of operation corresponds to said electric vehicle being turned off;

b) determining whether or not a power source external to said electric vehicle is connected to an ESS charging system, wherein if said power source is not connected to said ESS charging system and if said electric vehicle is in said second state of operation the method further comprises the steps of;

c) determining a current ESS temperature with at least one temperature sensor;

d) comparing said current ESS temperature with a preset temperature;

e) activating an ESS cooling system if said current ESS temperature is greater than said preset temperature;

f) deactivating said ESS cooling system if said current ESS temperature is lower than said preset temperature; and

g) repeating steps c) through f) until said current ESS temperature is lower than said preset temperature.

2. The method of claim 1, said ESS cooling system activating step further comprising the step of pumping a coolant through a coolant loop, said coolant loop in thermal communication with said ESS.

3. The method of claim 1, said ESS cooling system activating step further comprising the step of pumping a coolant through a coolant loop and through a radiator coupled to said coolant loop, said coolant loop in thermal communication with said ESS.

4. The method of claim 1, said ESS cooling system activating step further comprising the steps of:

pumping a coolant through a coolant loop and through a heat exchanger coupled to said coolant loop, said coolant loop in thermal communication with said ESS; and

operating a refrigeration system in thermal communication with said heat exchanger.

5. The method of claim 1, wherein prior to the ESS cooling system activating step, the method further comprises the steps of:

determining the difference between the current ESS temperature and the preset temperature; and

selecting a cooling system implementation based on said temperature difference.

6. A method of controlling the temperature of an electrical energy storage system (ESS) coupled to an electric powertrain of an electric vehicle, the method comprising the steps of:

a) monitoring an operational condition of said electric vehicle, wherein said operational condition is either in a first state of operation or a second state of operation, wherein said first state of operation corresponds to said electric vehicle being turned on, and wherein said second state of operation corresponds to said electric vehicle being turned off;

b) determining whether or not a power source external to said electric vehicle is connected to an ESS charging system, wherein if said power source is not connected to said ESS charging system and if said electric vehicle is in said second state of operation the method further comprises the steps of;

c) determining a current ESS temperature with at least one temperature sensor;

d) comparing said current ESS temperature with a preset temperature range;

e) activating a first ESS cooling system implementation if said current ESS temperature is within said preset temperature range;

f) activating a second ESS cooling system implementation if said current ESS temperature is greater than said preset temperature range;

g) terminating ESS cooling if said current ESS temperature is lower than said preset temperature range; and

h) repeating steps c) through g) until said current ESS temperature is lower than said preset temperature range.

7. The method of claim 6, wherein said first ESS cooling system implementation has a lower thermal capacity than said second ESS cooling system implementation, and wherein said first ESS cooling system implementation requires less power to operate than said second ESS cooling system implementation.

8. The method of claim 6, wherein said first ESS cooling system implementation activating step further comprises the step of pumping a coolant through a coolant loop and through a heat exchanger coupled to said coolant loop, said coolant loop in thermal communication with said ESS, and wherein said second ESS cooling system implementation activating step further comprises the steps of pumping said coolant through said coolant loop and through said heat exchanger coupled to said coolant loop, said coolant loop in thermal communication with said ESS, and operating a refrigeration system in thermal communication with said heat exchanger.

9. The method of claim 8, wherein each of said first and second ESS cooling system implementation activating steps further comprise the step of pumping said coolant through a radiator coupled to said coolant loop.

10. The method of claim 6, further comprising the steps of:

i) determining a current state of charge (SOC) of said ESS;

j) comparing said current SOC with a preset target SOC; and

k) terminating ESS cooling and bypassing steps c) through h) if said current SOC is lower than said preset target SOC.

11. The method of claim 10, wherein if said charging system is connected to said power source bypassing steps i) through k).