EP4562712A1 - Thermal system for battery pack, fast-charging system and method of fast-charging thereof - Google Patents

Thermal system for battery pack, fast-charging system and method of fast-charging thereof

Info

Publication number
EP4562712A1
EP4562712A1 EP23845846.7A EP23845846A EP4562712A1 EP 4562712 A1 EP4562712 A1 EP 4562712A1 EP 23845846 A EP23845846 A EP 23845846A EP 4562712 A1 EP4562712 A1 EP 4562712A1
Authority
EP
European Patent Office
Prior art keywords
battery pack
battery
charging
fast
bms
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP23845846.7A
Other languages
German (de)
French (fr)
Inventor
Msn KISHORE
Pramila Rao NILESHWAR
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
TVS Motor Co Ltd
Original Assignee
TVS Motor Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by TVS Motor Co Ltd filed Critical TVS Motor Co Ltd
Publication of EP4562712A1 publication Critical patent/EP4562712A1/en
Pending legal-status Critical Current

Links

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
    • 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
    • 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
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/64—Constructional details of batteries specially adapted for 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
    • 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
    • B60L58/12—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries responding to state of charge [SoC]
    • 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
    • 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
    • H01M10/44—Methods for charging or discharging
    • H01M10/443—Methods for charging or discharging in response to 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
    • H01M10/42—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
    • H01M10/62—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
    • H01M10/655—Solid structures for heat exchange or heat conduction
    • H01M10/6552—Closed pipes transferring heat by thermal conductivity or phase transition, e.g. heat pipes
    • 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
    • B60L53/11—DC charging controlled by the charging station, e.g. mode 4
    • 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

Definitions

  • the present invention relates to a thermal system for a battery pack. More particularly, the present invention relates to a fast-charging system and a method of fast-charging the battery pack using the thermal system.
  • fast charging has been one of the significant features that solves the issue of range anxiety for transition into an Electric Vehicle (EV) from existing Internal Combustion Engine (ICE) vehicles.
  • the fast charging of a battery pack depends on temperature, thermal, and electrochemical limits of cells in the battery.
  • Fast charging also depends on the construction or design of the cell and the way the cells are being used. As such, charging rate of a new cell is different as compared to an old cell of the battery pack.
  • connection between cells of the battery and a battery management system (BMS) is very crucial for efficient working of the battery pack, as the BMS monitors voltage, charging current, temperature, State of Charge (SoC), and the like of the cells for ensuring effective working and long life of the battery pack.
  • BMS battery management system
  • fast charging systems employ one common fast charging profile, irrespective of the SoC of the battery.
  • a constant current is provided to the battery for charging irrespective of SoC of the battery pack.
  • These fastcharging systems also do not include any means to determine state/health of individual cell of the battery pack and thus a common charging rate is provided.
  • Providing a constant current for fast charging to the battery will degrade the battery life and may lead to thermal runaway, which is undesirable. Consequently, the battery gets degraded within a year or two with age and duty cycle, thus affecting life of the battery pack.
  • a thermal system for a battery pack comprises a pump mounted to a battery casing of the battery pack.
  • a plurality of tubes is fluidly coupled to the pump and is mounted onto the battery casing of the battery pack.
  • the plurality of tubes is adapted to circulate a thermal fluid for maintaining a fast-charging temperature of the battery pack upon actuation of the pump.
  • a control unit is communicably coupled to the pump and to a Battery Management System (BMS).
  • BMS Battery Management System
  • the BMS is communicably coupled to one or more cells of the battery pack.
  • the control unit is adapted to control actuation of the pump based on one or more battery related parameters for circulating the thermal fluid within the plurality of tubes to maintain the fast-charging temperature of the battery pack during fastcharging of the battery pack.
  • the plurality of tubes is adapted to surround the battery casing of the battery pack thereby facilitating circulation of the thermal fluid around the battery pack uniformly.
  • At least one tube of the plurality of tubes is inserted into the casing of the battery pack for monitoring temperature of the battery pack.
  • an indication unit is mounted to the casing for indicating temperature of the battery pack, the indication unit being an audiovisual indication unit.
  • the one or more battery related parameters comprises a temperature of the battery pack, an ambient temperature of surroundings, a prior charging cycle of the battery pack, a prior discharging cycle of the battery pack, a state of charge of the battery pack and a degradation status of the battery pack.
  • a fast-charging system for a battery pack comprises the BMS communicably coupled to the one or more cells of the battery pack and is adapted to monitor the one or more battery related parameters of the battery pack.
  • the fast-charging system also comprises the thermal system comprising the pump mounted to the battery casing of the battery pack.
  • the plurality of tubes is fluidly coupled to the pump and is mounted onto the battery casing of the battery pack.
  • the plurality of tubes is adapted to circulate the thermal fluid for maintaining the fast-charging temperature of the battery pack upon actuation of the pump.
  • the control unit is communicably coupled to the pump and to the BMS.
  • the BMS is communicably coupled to the one or more cells of the battery pack.
  • the control unit is adapted to control actuation of the pump based on the one or more battery related parameters for circulating the thermal fluid within the plurality of tubes to maintain the fast-charging temperature of the battery pack during fastcharging of the battery pack.
  • a current supply device is communicably coupled to the BMS and adapted to be coupled to the battery pack. The current supply device is configured to supply current to the battery pack for fast-charging the battery pack, based on the one or more battery related parameters determined by the BMS.
  • the BMS is adapted to identify the battery pack based on an identification number provided on the battery pack.
  • the BMS upon identification is configured to retrieve the one or more battery related parameters of the battery pack.
  • the BMS is adapted to compute current required to be supplied from the current supply device to the battery pack, based on the one or more battery related parameters of the battery pack.
  • the BMS is configured to compute the fast-charging temperature of the battery pack based on current to be supplied and the one or more battery related parameters.
  • the BMS is configured to compute current required to be supplied from the current supply device to the battery pack and the fastcharging temperature, based on an input received from a user pertaining to a required fast charge range and a charging time through an input device.
  • a method for fast-charging the battery pack comprising identifying, by the BMS, the battery pack to be charged, through the identification number provided to the battery pack.
  • the BMS thereafter retrieves the one or more battery related parameters of the battery pack.
  • the BMS then computes the current to be supplied from the current supply device to the battery pack for fast-charging the battery pack based on the one or more battery related parameters.
  • the BMS subsequently computes the fast-charging temperature of the battery pack based on the current to be supplied and the one or more battery related parameters.
  • the control unit thereafter actuates the pump for circulating the thermal fluid within the plurality of tubes to maintain the fast-charging temperature of the battery pack.
  • the BMS then operates the current supply device for supplying the computed current to the battery pack for fast-charging the battery pack.
  • Figure 1 is a schematic perspective view of a thermal system for a battery pack, in accordance with an exemplary embodiment of the present disclosure.
  • Figure 2 is a perspective view of the thermal system mounted onto the battery pack, in accordance with an exemplary embodiment of the present disclosure.
  • Figure 3 is a front view of the thermal system mounted onto the battery pack, in accordance with an exemplary embodiment of the present disclosure.
  • Figure 4 is a side view of the thermal system mounted onto the battery pack, in accordance with an exemplary embodiment of the present disclosure.
  • FIG. 5 is a block diagram of a fast-charging system, in accordance with an exemplary embodiment of the present disclosure.
  • FIG. 6 is a flow diagram of a method for fast-charging a battery pack, in accordance with an exemplary embodiment of the present disclosure.
  • FIG. 1 illustrates a thermal system 100 for a battery pack 102 (shown in Figures 2, 3 and 4), in accordance with an exemplary embodiment of the present disclosure.
  • the thermal system 100 is adapted to maintain a fastcharging temperature of the battery pack 102, thereby preventing degradation of the battery pack 102 during a fast-charging event.
  • the thermal system 100 comprises a housing 122 adapted to be mounted onto the battery casing 106.
  • the housing 122 is adapted to accommodate or enclose components of the thermal system 100.
  • the housing 122 may be a box-shaped member adapted to enclose components of the thermal system 100.
  • the housing 122 is mounted onto a side surface of the battery casing 106.
  • the housing 122 accommodates a pump 104, a motor (not shown) and a control unit 110, which is communicably coupled to the pump 104.
  • the pump 104 may be directly mounted to the battery casing 106 of the battery pack 102 instead of the housing 122.
  • the thermal system 100 further comprises a plurality of tubes 108 that is fluidly coupled to the pump 104.
  • the plurality of tubes 108 is mounted onto the battery casing 106 of the battery pack 102.
  • the plurality of tubes 108 surrounds the battery casing 106, while ensuring thermal contact.
  • the plurality of tubes 108 is adapted to circulate a thermal fluid for maintaining the fast-charging temperature of the battery pack 102, upon actuation of the pump 104.
  • the plurality of tubes 108 surrounds the battery casing 106 so that, the plurality of tubes 108 is capable of circulating the thermal fluid around the battery pack 102 uniformly for maintaining the fastcharging temperature.
  • dimensions of the plurality of tubes 108 are selected based on flow requirements of the thermal fluid.
  • the plurality of tubes 108 is a cascaded tubular structure.
  • the profile and configuration of the plurality of tubes 108 may be selected as per design feasibility and requirement.
  • at least one tube 108a of the plurality of tubes 108 is inserted into the battery casing 106 for monitoring temperature of the battery pack 102.
  • the at least one tube 108a may contact the one or more cells (not shown) in the battery pack 102 for monitoring temperature of the battery pack 102.
  • the thermal fluid may be a refrigerant that is capable of extracting heat from the battery pack 102 through the battery casing 106.
  • the thermal fluid may be a fluid adapted to provide heat to the battery pack 102 through the battery casing 106.
  • a plurality of fin members 106a (shown in Figures 2, 3 and 4) is provided on an outer surface of the battery casing 106.
  • the plurality of fin members 106a are configured to increase the surface area available for contact with the ambient air, thereby ensuring heat dissipation.
  • the plurality of tubes 108 may be coupled to a heat exchanger (not shown). As such, based on the temperature to be maintained on the battery pack 102, the thermal fluid may be cooled or heated for ensuring that the battery pack 102 is maintained at the fast-charging temperature.
  • the fast-charging temperature of the battery pack 102 pertains to the temperature of the battery pack 102 that is required to be maintained for ensuring minimal or no degradation of the battery pack 102 during the fast-charging event.
  • control unit 1 10 accommodated within the housing 122 is also communicably coupled to a battery management system (BMS) 1 12 (shown in Figure 5), which may in-turn be communicably coupled to one or more cells (not shown) of the battery pack 102.
  • BMS battery management system
  • the control unit 110 is communicably coupled to the BMS 112 via a wired connection or a wireless connection.
  • the control unit 110 is adapted to control actuation of the pump 104 based on one or more battery related parameters 114 for circulating the thermal fluid within the plurality of tubes 108 to maintain the fast-charging temperature of the battery pack 102 during the fast-charging of the battery pack 102.
  • the one or more battery related parameters 114 comprises a temperature of the battery pack 102, an ambient temperature of surroundings, a prior charging cycle of the battery pack 102, a prior discharging cycle of the battery pack 102, a State of Charge (SoC) of the battery pack 102 and a degradation status of the battery pack 102.
  • SoC State of Charge
  • the prior charging cycle of the battery pack 102 comprises data pertaining to previous charging event of the battery pack 102.
  • the data may include number of charging cycles, duration of charging, the current supplied for charging, quantity of charge of the battery pack 102 and the like.
  • the prior discharging cycle of the battery pack 102 comprises data pertaining to the discharging rate of the battery pack 102.
  • the data may include the rate of discharging of the battery pack 102, usage of the battery pack 102 during the discharging event and the like.
  • the state of charge of the battery pack 102 comprises data pertaining to charge level of the battery pack 102.
  • control unit 110 may comprise one or more additional components such as, but not limited to, an input/output module (not shown), a pre-processing module (not shown) and an analytic module (not shown).
  • control unit 1 10 is in communication with the components such as the processing module (not shown) and the analytic module (not shown).
  • the control unit 1 10 may be embodied as a multi-core processor, a single core processor, or a combination of one or more multi-core processors and one or more single core processors.
  • control unit 1 10 is embodied as one or more of various processing devices or modules, such as a coprocessor, a microprocessor, a controller, a digital signal processor (DSP), a processing circuitry with or without an accompanying DSP, or various other processing devices including integrated circuits such as, for example, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a microcontroller unit (MCU), a hardware accelerator, a special-purpose computer chip, or the like.
  • the control unit 1 10 may be configured to execute hard-coded functionality.
  • control unit 1 10 may be embodied as an executor of instructions, where the instructions are specifically configured to the control unit 1 10 to perform the steps or operations described herein for fast-charging the battery pack 102.
  • control unit 110 is communicably coupled to a memory unit (not shown).
  • the memory is capable of storing information processed by the control unit 110, data pertaining to the one or more battery related parameters 114 and the data received and/or processed by the BMS 112.
  • the memory unit is embodied as one or more volatile memory devices, one or more non-volatile memory devices and/or combination thereof, such as magnetic storage devices, optical-magnetic storage devices and the like as per design feasibility and requirement.
  • the memory unit communicates with the control unit 1 10 via suitable interfaces such as Advanced Technology Attachment (ATA) adapter, a Serial ATA [SATA] adapter, a Small Computer System Interface [SCSI] adapter, a network adapter or any other component enabling communication between the memory unit and the control unit 1 10.
  • ATA Advanced Technology Attachment
  • SATA Serial ATA
  • SCSI Small Computer System Interface
  • network adapter any other component enabling communication between the memory unit and the control unit 1 10.
  • the thermal system 100 comprises an indication unit 116 mounted on the housing 122.
  • the indication unit 116 is adapted to indicate temperature of the battery pack 102.
  • the indication unit 116 is an audio-visual indication unit 116 that may provide an audio alert or a visual alert or an audio-visual alert pertaining to temperature of the battery pack 102.
  • the indication unit 116 may be a color emitting device, wherein the indication unit 1 16 is configured to emit a green color when temperature of the battery pack 102 during fast-charging is within the fastcharging temperature.
  • the indication unit 116 may be configured to emit a red color when temperature of the battery pack 102 during fast-charging is beyond the fast-charging temperature.
  • FIG. 5 a fast-charging system 118 for the battery pack 102 is depicted.
  • the fast-charging system 1 18 is adapted to fast-charge the battery pack 102, without degrading life of the battery pack 102.
  • the fast-charging system 100 comprises the BMS 112, which may be communicably coupled to the one or more cells of the battery pack 102.
  • the BMS 112 is adapted to monitor the one or more battery related parameters 114 of the battery pack 102, for determining health of the battery pack 102.
  • the BMS 112 is communicably coupled to the one or more cells of the battery pack 102 via the wired connection or the wireless connection, for monitoring the one or more battery related parameters 114.
  • the BMS 112 is positioned inside the battery pack 102.
  • the BMS 112 may include components identical to the control unit 1 10 for receiving and processing data from the one or more cells of the battery pack 102.
  • the fast-charging system 118 further comprises the thermal system 100 described in Figures 1 -4, wherein the BMS 1 12 is communicably coupled to the control unit 110.
  • the BMS 112 is capable of controlling operation of the thermal system 100.
  • the BMS 112 controls operation of the thermal system 100 through the control unit 1 10.
  • the BMS 1 12 and the control unit 110 are capable of exchanging information as per feasibility and requirement.
  • the BMS 112 is adapted to receive the one or more battery related parameters 114 as well as configuration or design details of the battery pack 102 based on an identification number (not shown) assigned to the battery pack 102.
  • the BMS 112 is capable of retrieving data such as type of the battery pack 102, charging capacity and the like, upon connection of the battery pack 102 with the fast-charging system 118.
  • the fast-charging system 118 comprises a current supply device 120, which is communicably coupled to the BMS 112.
  • the current supply device 120 is configured to supply current to the battery pack 102 for fast-charging the battery pack 102, based on the one or more battery related parameters determined by the BMS 112.
  • the current supply device 120 is a part of a charging station (not shown) or a charging device (not shown) of a charging terminal (not shown).
  • the BMS 112 upon connection with the current supply device 120 of the charging station, determines the one or more battery related parameters of the battery pack 102 for fast-charging.
  • the BMS 1 12 is adapted to determine charging level of the battery pack 102, the previous charging cycle of the battery pack 102, ambient temperature of the surroundings, the previous discharging cycle of the battery pack 102 and temperature of the battery pack 102, upon connection with the current supply device 120.
  • the BMS 112 may be communicably coupled to an input device 124 provided in the charging station or the charging terminal.
  • the input device 124 may be a touchscreen device mounted on a charging device (not shown) of the charging station or the charging terminal.
  • the input device 124 is adapted to receive instructions from the user regarding the charging requirement and/or travelling distance and/or charging time for charging the battery pack 102. As an example, if the user is required to travel 50 kms and the time available for charging is 10 mins, the user may input as 50kms and charging time as 10 mins in the input device 124. Based on the input received and the ambient temperature of the surroundings, the BMS 112 computes the fast-charging temperature and the charging current required to be provided. In another embodiment, the BMS 112 may be configured to receive data from the charging station or the charging terminal provided by the user through the input device 124.
  • the BMS 112 may compute the fast-charging temperature to be maintained as 50 degrees and the fast-charging current to be 25A. Accordingly, the BMS 112 provides a feedback signal to the current supply device 120 for supplying 25A current to the battery pack 102. At the same time, the BMS 1 12 provides another feedback signal to the thermal system 100 and accordingly operates the pump 104 to circulate the thermal fluid around the battery pack 102 to ensure that the temperature of the battery pack 102 does not exceed 50 degrees and fast charging is achieved within specified time.
  • Figure 6 illustrates a flow diagram of a method 600 for fast-charging the battery pack 102, in accordance with an exemplary embodiment of the present disclosure.
  • the BMS 112 identifies the battery pack 102 through the identification number, upon connection of the battery pack 102 with a current supply device 120. Upon identifying the battery pack 102, at step 604, the BMS 112 retrieves the one or more battery related parameters 114 corresponding to the battery pack 102 along with the design or configuration details of the battery pack 102.
  • the BMS 112 estimates deterioration level of the battery pack 102 by determining a lithium plating status and resistance increase in the battery pack 102. Upon determining the deterioration details of the battery pack 102, the method 600 moves to step 608.
  • the BMS 112 computes the current required to be supplied from the current supply device 120 to the battery pack 102 for charging the battery pack 102. From the above example, the BMS 112 may compute the charging current to be 25A.
  • the BMS 1 12 receives a fast-charge range (/.e. distance) and a charge time through the input device 124 from the user from a charging station.
  • a fast-charge range /.e. distance
  • the user may input the fast charge range as 50 kms and the charge time to be 10 mins.
  • the method 600 moves to step 612.
  • the BMS 112 measures the initial SoC and temperature of the battery pack 102.
  • the BMS 112 Based on the temperature and the SoC measurement, the BMS 112 computes the fast-charging temperature of the battery pack 102 at step 614. From the above example, if the ambient temperature is 25 degrees, temperature is 35 degrees and SoC of the battery pack 102 is 10 percent of maximum valve, the BMS 112 may compute the fast-charging temperature as 50 degrees. In an embodiment, the BMS 1 12 may determine the fast-charging temperature based on the capacity of the battery pack 102. In other words, if the configuration details of the battery pack 102 includes 50 degrees as the maximum rated temperature that the battery pack 102 can withstand, then the Y1
  • BMS 1 12 computes the fast-charging temperature well below 50 degrees, for. e.g. as 40 degrees.
  • the BMS 1 12 communicates with the control unit 110 to control operation of the pump 104.
  • the control unit 110 actuates the pump 104 according to the fast-charging temperature to be maintained.
  • the thermal fluid circulates within the plurality of tubes 108 for maintaining the fast-charging temperature.
  • the pump 104 is suitably operated by the control unit 1 10 in order to supply colder thermal fluid for maintaining the fast-charging temperature.
  • the pump 104 may be operated to supply warmer thermal fluid for maintaining the fast-charging temperature.
  • the warmer or colder thermal fluid may be generated based on the heat exchanger fluidly coupled to the plurality of tubes 108.
  • the BMS 112 operates the current supply device 120 to supply the computed current to the battery pack for fast-charging. Thereafter, at step 620, the BMS 112 re-estimates the current supplied based on real-time retrieval of the one or more battery related parameters 114 of the battery pack 102. As such, if a battery life is being affected due to the charging current supplied, the BMS 112 alters the charging current for safety of the battery pack
  • the claimed invention as disclosed above is not routine, conventional or well understood in the art, as the claimed aspects enable the following solutions to the existing problems in conventional technologies.
  • the claimed aspects of providing the thermal system 100 including the control unit 110 for monitoring temperature of the battery pack 102 ensures safety of the battery pack 102 during fast-charging. Also, due to real-time monitoring of the one or more battery related parameters 114 during fast-charging, degradation of the battery pack 102 is minimized, thereby extending life of the battery pack 102. Additionally, due to maintenance of the battery pack 102 during charging, the performance of the battery pack 102 is improved.

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Abstract

The present disclosure provides a thermal system (100) for a battery pack (102) comprising a pump (104) and a plurality of tubes (108) fluidly coupled to the pump (104) and mounted onto the battery casing (106) of the battery pack (102). The plurality of tubes (108) is adapted to circulate thermal fluid for maintaining a fast-charging temperature of the battery pack (102). A control unit (110) is communicably coupled to the pump (104) and to a BMS (112). The control unit (110) is adapted to control actuation of the pump (104) based on one or more battery related parameters (114) for circulating thermal fluid within plurality of tubes (108) to maintain fast-charging temperature of the battery pack (102) during fast-charging of battery pack (102). The thermal system (100) is adapted to reduce temperature of battery pack (102) during fast- charging, thereby minimizing deterioration of battery pack (102).

Description

TITLE OF INVENTION
Thermal System for Battery Pack, Fast-Charging System and Method of Fast-charging Thereof
FIELD OF THE INVENTION
[001] The present invention relates to a thermal system for a battery pack. More particularly, the present invention relates to a fast-charging system and a method of fast-charging the battery pack using the thermal system. BACKGROUND OF THE INVENTION
[002] Generally, fast charging has been one of the significant features that solves the issue of range anxiety for transition into an Electric Vehicle (EV) from existing Internal Combustion Engine (ICE) vehicles. The fast charging of a battery pack depends on temperature, thermal, and electrochemical limits of cells in the battery. Fast charging also depends on the construction or design of the cell and the way the cells are being used. As such, charging rate of a new cell is different as compared to an old cell of the battery pack. Further, connection between cells of the battery and a battery management system (BMS) is very crucial for efficient working of the battery pack, as the BMS monitors voltage, charging current, temperature, State of Charge (SoC), and the like of the cells for ensuring effective working and long life of the battery pack. [003] So far, in existing art, fast charging systems employ one common fast charging profile, irrespective of the SoC of the battery. In other words, in conventional fast charging systems, a constant current is provided to the battery for charging irrespective of SoC of the battery pack. These fastcharging systems also do not include any means to determine state/health of individual cell of the battery pack and thus a common charging rate is provided. Providing a constant current for fast charging to the battery, will degrade the battery life and may lead to thermal runaway, which is undesirable. Consequently, the battery gets degraded within a year or two with age and duty cycle, thus affecting life of the battery pack.
[004] In view of the above, there is a need for a thermal system for the battery pack, a fast-charging system and a method of fast-charging the battery pack, which addresses one or more limitations stated above.
SUMMARY OF THE INVENTION
[005] In one aspect, a thermal system for a battery pack is disclosed. The thermal system comprises a pump mounted to a battery casing of the battery pack. A plurality of tubes is fluidly coupled to the pump and is mounted onto the battery casing of the battery pack. The plurality of tubes is adapted to circulate a thermal fluid for maintaining a fast-charging temperature of the battery pack upon actuation of the pump. A control unit is communicably coupled to the pump and to a Battery Management System (BMS). The BMS is communicably coupled to one or more cells of the battery pack. The control unit is adapted to control actuation of the pump based on one or more battery related parameters for circulating the thermal fluid within the plurality of tubes to maintain the fast-charging temperature of the battery pack during fastcharging of the battery pack.
[006] In an embodiment, the plurality of tubes is adapted to surround the battery casing of the battery pack thereby facilitating circulation of the thermal fluid around the battery pack uniformly.
[007] In an embodiment, at least one tube of the plurality of tubes is inserted into the casing of the battery pack for monitoring temperature of the battery pack.
[008] In an embodiment, an indication unit is mounted to the casing for indicating temperature of the battery pack, the indication unit being an audiovisual indication unit.
[009] In an embodiment, the one or more battery related parameters comprises a temperature of the battery pack, an ambient temperature of surroundings, a prior charging cycle of the battery pack, a prior discharging cycle of the battery pack, a state of charge of the battery pack and a degradation status of the battery pack.
[010] In another aspect, a fast-charging system for a battery pack is disclosed. The fast-charging system comprises the BMS communicably coupled to the one or more cells of the battery pack and is adapted to monitor the one or more battery related parameters of the battery pack. The fast-charging system also comprises the thermal system comprising the pump mounted to the battery casing of the battery pack. The plurality of tubes is fluidly coupled to the pump and is mounted onto the battery casing of the battery pack. The plurality of tubes is adapted to circulate the thermal fluid for maintaining the fast-charging temperature of the battery pack upon actuation of the pump. The control unit is communicably coupled to the pump and to the BMS. The BMS is communicably coupled to the one or more cells of the battery pack. The control unit is adapted to control actuation of the pump based on the one or more battery related parameters for circulating the thermal fluid within the plurality of tubes to maintain the fast-charging temperature of the battery pack during fastcharging of the battery pack. A current supply device is communicably coupled to the BMS and adapted to be coupled to the battery pack. The current supply device is configured to supply current to the battery pack for fast-charging the battery pack, based on the one or more battery related parameters determined by the BMS.
[011] In an embodiment, the BMS is adapted to identify the battery pack based on an identification number provided on the battery pack. The BMS upon identification is configured to retrieve the one or more battery related parameters of the battery pack.
[012] In an embodiment, the BMS is adapted to compute current required to be supplied from the current supply device to the battery pack, based on the one or more battery related parameters of the battery pack. [013] In an embodiment, the BMS is configured to compute the fast-charging temperature of the battery pack based on current to be supplied and the one or more battery related parameters.
[014] In an embodiment, the BMS is configured to compute current required to be supplied from the current supply device to the battery pack and the fastcharging temperature, based on an input received from a user pertaining to a required fast charge range and a charging time through an input device.
[015] In another aspect, a method for fast-charging the battery pack is disclosed. The method comprising identifying, by the BMS, the battery pack to be charged, through the identification number provided to the battery pack. The BMS thereafter retrieves the one or more battery related parameters of the battery pack. The BMS then computes the current to be supplied from the current supply device to the battery pack for fast-charging the battery pack based on the one or more battery related parameters. The BMS, subsequently computes the fast-charging temperature of the battery pack based on the current to be supplied and the one or more battery related parameters. The control unit thereafter actuates the pump for circulating the thermal fluid within the plurality of tubes to maintain the fast-charging temperature of the battery pack. The BMS then operates the current supply device for supplying the computed current to the battery pack for fast-charging the battery pack. BRIEF DESCRIPTION OF THE DRAWINGS
[016] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 is a schematic perspective view of a thermal system for a battery pack, in accordance with an exemplary embodiment of the present disclosure.
Figure 2 is a perspective view of the thermal system mounted onto the battery pack, in accordance with an exemplary embodiment of the present disclosure.
Figure 3 is a front view of the thermal system mounted onto the battery pack, in accordance with an exemplary embodiment of the present disclosure.
Figure 4 is a side view of the thermal system mounted onto the battery pack, in accordance with an exemplary embodiment of the present disclosure.
Figure 5 is a block diagram of a fast-charging system, in accordance with an exemplary embodiment of the present disclosure.
Figure 6 is a flow diagram of a method for fast-charging a battery pack, in accordance with an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION
[017] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder.
[018] Figure 1 illustrates a thermal system 100 for a battery pack 102 (shown in Figures 2, 3 and 4), in accordance with an exemplary embodiment of the present disclosure. The thermal system 100 is adapted to maintain a fastcharging temperature of the battery pack 102, thereby preventing degradation of the battery pack 102 during a fast-charging event.
[019] Referring to Figures 2-4 in conjunction with Figure 1 , the thermal system 100 comprises a housing 122 adapted to be mounted onto the battery casing 106. The housing 122 is adapted to accommodate or enclose components of the thermal system 100. In the present embodiment, the housing 122 may be a box-shaped member adapted to enclose components of the thermal system 100. In an embodiment, the housing 122 is mounted onto a side surface of the battery casing 106. The housing 122 accommodates a pump 104, a motor (not shown) and a control unit 110, which is communicably coupled to the pump 104. In an embodiment, the pump 104 may be directly mounted to the battery casing 106 of the battery pack 102 instead of the housing 122.
[020] The thermal system 100 further comprises a plurality of tubes 108 that is fluidly coupled to the pump 104. The plurality of tubes 108 is mounted onto the battery casing 106 of the battery pack 102. In an embodiment, the plurality of tubes 108 surrounds the battery casing 106, while ensuring thermal contact. The plurality of tubes 108 is adapted to circulate a thermal fluid for maintaining the fast-charging temperature of the battery pack 102, upon actuation of the pump 104. In an embodiment, the plurality of tubes 108 surrounds the battery casing 106 so that, the plurality of tubes 108 is capable of circulating the thermal fluid around the battery pack 102 uniformly for maintaining the fastcharging temperature. In an embodiment, dimensions of the plurality of tubes 108 are selected based on flow requirements of the thermal fluid. In another embodiment, the plurality of tubes 108 is a cascaded tubular structure. Alternatively, the profile and configuration of the plurality of tubes 108 may be selected as per design feasibility and requirement. Also, at least one tube 108a of the plurality of tubes 108 is inserted into the battery casing 106 for monitoring temperature of the battery pack 102. The at least one tube 108a may contact the one or more cells (not shown) in the battery pack 102 for monitoring temperature of the battery pack 102.
[021] In an embodiment, the thermal fluid may be a refrigerant that is capable of extracting heat from the battery pack 102 through the battery casing 106. In another embodiment, the thermal fluid may be a fluid adapted to provide heat to the battery pack 102 through the battery casing 106.
[022] In an embodiment, a plurality of fin members 106a (shown in Figures 2, 3 and 4) is provided on an outer surface of the battery casing 106. The plurality of fin members 106a are configured to increase the surface area available for contact with the ambient air, thereby ensuring heat dissipation. [023] In an embodiment, the plurality of tubes 108 may be coupled to a heat exchanger (not shown). As such, based on the temperature to be maintained on the battery pack 102, the thermal fluid may be cooled or heated for ensuring that the battery pack 102 is maintained at the fast-charging temperature.
[024] In an embodiment, the fast-charging temperature of the battery pack 102 pertains to the temperature of the battery pack 102 that is required to be maintained for ensuring minimal or no degradation of the battery pack 102 during the fast-charging event.
[025] Further, the control unit 1 10 accommodated within the housing 122 is also communicably coupled to a battery management system (BMS) 1 12 (shown in Figure 5), which may in-turn be communicably coupled to one or more cells (not shown) of the battery pack 102. In an embodiment, the control unit 110 is communicably coupled to the BMS 112 via a wired connection or a wireless connection. The control unit 110 is adapted to control actuation of the pump 104 based on one or more battery related parameters 114 for circulating the thermal fluid within the plurality of tubes 108 to maintain the fast-charging temperature of the battery pack 102 during the fast-charging of the battery pack 102.
[026] In an embodiment, the one or more battery related parameters 114 comprises a temperature of the battery pack 102, an ambient temperature of surroundings, a prior charging cycle of the battery pack 102, a prior discharging cycle of the battery pack 102, a State of Charge (SoC) of the battery pack 102 and a degradation status of the battery pack 102.
[027] In an embodiment, the prior charging cycle of the battery pack 102 comprises data pertaining to previous charging event of the battery pack 102. The data may include number of charging cycles, duration of charging, the current supplied for charging, quantity of charge of the battery pack 102 and the like.
[028] In an embodiment, the prior discharging cycle of the battery pack 102 comprises data pertaining to the discharging rate of the battery pack 102. The data may include the rate of discharging of the battery pack 102, usage of the battery pack 102 during the discharging event and the like.
[029] In an embodiment, the state of charge of the battery pack 102 comprises data pertaining to charge level of the battery pack 102.
[030] In some embodiments, the control unit 110 may comprise one or more additional components such as, but not limited to, an input/output module (not shown), a pre-processing module (not shown) and an analytic module (not shown).
[031] In an embodiment, the control unit 1 10 is in communication with the components such as the processing module (not shown) and the analytic module (not shown). In another embodiment, the control unit 1 10 may be embodied as a multi-core processor, a single core processor, or a combination of one or more multi-core processors and one or more single core processors. For example, the control unit 1 10 is embodied as one or more of various processing devices or modules, such as a coprocessor, a microprocessor, a controller, a digital signal processor (DSP), a processing circuitry with or without an accompanying DSP, or various other processing devices including integrated circuits such as, for example, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a microcontroller unit (MCU), a hardware accelerator, a special-purpose computer chip, or the like. In yet another embodiment, the control unit 1 10 may be configured to execute hard-coded functionality. In still another embodiment, the control unit 1 10 may be embodied as an executor of instructions, where the instructions are specifically configured to the control unit 1 10 to perform the steps or operations described herein for fast-charging the battery pack 102.
[032] Further, the control unit 110 is communicably coupled to a memory unit (not shown). The memory is capable of storing information processed by the control unit 110, data pertaining to the one or more battery related parameters 114 and the data received and/or processed by the BMS 112. The memory unit is embodied as one or more volatile memory devices, one or more non-volatile memory devices and/or combination thereof, such as magnetic storage devices, optical-magnetic storage devices and the like as per design feasibility and requirement. The memory unit communicates with the control unit 1 10 via suitable interfaces such as Advanced Technology Attachment (ATA) adapter, a Serial ATA [SATA] adapter, a Small Computer System Interface [SCSI] adapter, a network adapter or any other component enabling communication between the memory unit and the control unit 1 10.
[033] Further, the thermal system 100 comprises an indication unit 116 mounted on the housing 122. The indication unit 116 is adapted to indicate temperature of the battery pack 102. In an embodiment, the indication unit 116 is an audio-visual indication unit 116 that may provide an audio alert or a visual alert or an audio-visual alert pertaining to temperature of the battery pack 102. In an embodiment, the indication unit 116 may be a color emitting device, wherein the indication unit 1 16 is configured to emit a green color when temperature of the battery pack 102 during fast-charging is within the fastcharging temperature. The indication unit 116 may be configured to emit a red color when temperature of the battery pack 102 during fast-charging is beyond the fast-charging temperature.
[034] Referring to Figure 5 in conjunction with Figures 1 -4, a fast-charging system 118 for the battery pack 102 is depicted. The fast-charging system 1 18 is adapted to fast-charge the battery pack 102, without degrading life of the battery pack 102.
[035] The fast-charging system 100 comprises the BMS 112, which may be communicably coupled to the one or more cells of the battery pack 102. The BMS 112 is adapted to monitor the one or more battery related parameters 114 of the battery pack 102, for determining health of the battery pack 102. In an embodiment, the BMS 112 is communicably coupled to the one or more cells of the battery pack 102 via the wired connection or the wireless connection, for monitoring the one or more battery related parameters 114. In the present embodiment, the BMS 112 is positioned inside the battery pack 102. The BMS 112 may include components identical to the control unit 1 10 for receiving and processing data from the one or more cells of the battery pack 102.
[036] The fast-charging system 118 further comprises the thermal system 100 described in Figures 1 -4, wherein the BMS 1 12 is communicably coupled to the control unit 110. As such, the BMS 112 is capable of controlling operation of the thermal system 100. In an embodiment, the BMS 112 controls operation of the thermal system 100 through the control unit 1 10. Also, the BMS 1 12 and the control unit 110 are capable of exchanging information as per feasibility and requirement.
[037] In an embodiment, the BMS 112 is adapted to receive the one or more battery related parameters 114 as well as configuration or design details of the battery pack 102 based on an identification number (not shown) assigned to the battery pack 102. As such, the BMS 112 is capable of retrieving data such as type of the battery pack 102, charging capacity and the like, upon connection of the battery pack 102 with the fast-charging system 118.
[038] Additionally, the fast-charging system 118 comprises a current supply device 120, which is communicably coupled to the BMS 112. The current supply device 120 is configured to supply current to the battery pack 102 for fast-charging the battery pack 102, based on the one or more battery related parameters determined by the BMS 112. In an embodiment, the current supply device 120 is a part of a charging station (not shown) or a charging device (not shown) of a charging terminal (not shown). The BMS 112 upon connection with the current supply device 120 of the charging station, determines the one or more battery related parameters of the battery pack 102 for fast-charging. As an example, the BMS 1 12 is adapted to determine charging level of the battery pack 102, the previous charging cycle of the battery pack 102, ambient temperature of the surroundings, the previous discharging cycle of the battery pack 102 and temperature of the battery pack 102, upon connection with the current supply device 120.
[039] In an embodiment, the BMS 112 may be communicably coupled to an input device 124 provided in the charging station or the charging terminal. In an embodiment, the input device 124 may be a touchscreen device mounted on a charging device (not shown) of the charging station or the charging terminal. The input device 124 is adapted to receive instructions from the user regarding the charging requirement and/or travelling distance and/or charging time for charging the battery pack 102. As an example, if the user is required to travel 50 kms and the time available for charging is 10 mins, the user may input as 50kms and charging time as 10 mins in the input device 124. Based on the input received and the ambient temperature of the surroundings, the BMS 112 computes the fast-charging temperature and the charging current required to be provided. In another embodiment, the BMS 112 may be configured to receive data from the charging station or the charging terminal provided by the user through the input device 124.
[040] As an example, the BMS 112 may compute the fast-charging temperature to be maintained as 50 degrees and the fast-charging current to be 25A. Accordingly, the BMS 112 provides a feedback signal to the current supply device 120 for supplying 25A current to the battery pack 102. At the same time, the BMS 1 12 provides another feedback signal to the thermal system 100 and accordingly operates the pump 104 to circulate the thermal fluid around the battery pack 102 to ensure that the temperature of the battery pack 102 does not exceed 50 degrees and fast charging is achieved within specified time.
[041 ] Figure 6 illustrates a flow diagram of a method 600 for fast-charging the battery pack 102, in accordance with an exemplary embodiment of the present disclosure.
[042] At step 602, the BMS 112 identifies the battery pack 102 through the identification number, upon connection of the battery pack 102 with a current supply device 120. Upon identifying the battery pack 102, at step 604, the BMS 112 retrieves the one or more battery related parameters 114 corresponding to the battery pack 102 along with the design or configuration details of the battery pack 102.
[043] At step 606, the BMS 112 estimates deterioration level of the battery pack 102 by determining a lithium plating status and resistance increase in the battery pack 102. Upon determining the deterioration details of the battery pack 102, the method 600 moves to step 608.
[044] At step 608, the BMS 112 computes the current required to be supplied from the current supply device 120 to the battery pack 102 for charging the battery pack 102. From the above example, the BMS 112 may compute the charging current to be 25A.
[045] Thereafter, at step 610, the BMS 1 12 receives a fast-charge range (/.e. distance) and a charge time through the input device 124 from the user from a charging station. In view of the example already mentioned above, the user may input the fast charge range as 50 kms and the charge time to be 10 mins. Upon receiving the inputs through the input device 124, the method 600 moves to step 612. At step 612, the BMS 112 measures the initial SoC and temperature of the battery pack 102.
[046] Based on the temperature and the SoC measurement, the BMS 112 computes the fast-charging temperature of the battery pack 102 at step 614. From the above example, if the ambient temperature is 25 degrees, temperature is 35 degrees and SoC of the battery pack 102 is 10 percent of maximum valve, the BMS 112 may compute the fast-charging temperature as 50 degrees. In an embodiment, the BMS 1 12 may determine the fast-charging temperature based on the capacity of the battery pack 102. In other words, if the configuration details of the battery pack 102 includes 50 degrees as the maximum rated temperature that the battery pack 102 can withstand, then the Y1
BMS 1 12 computes the fast-charging temperature well below 50 degrees, for. e.g. as 40 degrees.
[047] Thereafter at step 616, the BMS 1 12 communicates with the control unit 110 to control operation of the pump 104. At this scenario, the control unit 110 actuates the pump 104 according to the fast-charging temperature to be maintained. Upon actuation of the pump 104, the thermal fluid circulates within the plurality of tubes 108 for maintaining the fast-charging temperature. In an embodiment, if the ambient temperature is hot, say 40 degrees, the pump 104 is suitably operated by the control unit 1 10 in order to supply colder thermal fluid for maintaining the fast-charging temperature. In another embodiment, during cold weather conditions, say 20 degree, the pump 104 may be operated to supply warmer thermal fluid for maintaining the fast-charging temperature. The warmer or colder thermal fluid may be generated based on the heat exchanger fluidly coupled to the plurality of tubes 108.
[048] At step 618, the BMS 112 operates the current supply device 120 to supply the computed current to the battery pack for fast-charging. Thereafter, at step 620, the BMS 112 re-estimates the current supplied based on real-time retrieval of the one or more battery related parameters 114 of the battery pack 102. As such, if a battery life is being affected due to the charging current supplied, the BMS 112 alters the charging current for safety of the battery pack
102. [049] The claimed invention as disclosed above is not routine, conventional or well understood in the art, as the claimed aspects enable the following solutions to the existing problems in conventional technologies. Specifically, the claimed aspects of providing the thermal system 100 including the control unit 110 for monitoring temperature of the battery pack 102 ensures safety of the battery pack 102 during fast-charging. Also, due to real-time monitoring of the one or more battery related parameters 114 during fast-charging, degradation of the battery pack 102 is minimized, thereby extending life of the battery pack 102. Additionally, due to maintenance of the battery pack 102 during charging, the performance of the battery pack 102 is improved.
Reference numerals

Claims

CLAIMS:
1. A thermal system (100) for a battery pack (102), the thermal system (100) comprising: a pump (104) mounted to a battery casing (106) of the battery pack (102); a plurality of tubes (108) fluidly coupled to the pump (104) and mounted onto the battery casing (106) of the battery pack (102), the plurality of tubes (108) being adapted to circulate a thermal fluid for maintaining a fastcharging temperature of the battery pack (102), upon actuation of the pump (104); and a control unit (110) communicably coupled to the pump (104) and to a battery management system (BMS) (112), the BMS (112) being communicably coupled to one or more cells of the battery pack (102); wherein, the control unit (110) is adapted to control actuation of the pump (104) based on one or more battery related parameters (114) for circulating the thermal fluid within the plurality of tubes (108) to maintain the fast-charging temperature of the battery pack (102) during fast-charging of the battery pack (102).
2. The thermal system (100) as claimed in claim 1 , wherein the plurality of tubes (108) are adapted to surround the battery casing (106) of the battery pack (102), thereby facilitating circulation of the thermal fluid around the battery pack (102) uniformly.
3. The thermal system (100) as claimed in claim 1 , wherein at least one tube (108a) of the plurality of tubes (108) is inserted into the battery casing (106) of the battery pack (102) for monitoring temperature of the battery pack (102).
4. The thermal system (100) as claimed in claim 1 comprises an indication unit (116) mounted to the battery casing (106) for indicating temperature of the battery pack (102), the indication unit (116) being an audio-visual indication unit.
5. The thermal system (100) as claimed in claim 1 , wherein the one or more battery related parameters (114) comprises: a temperature of the battery pack (102); an ambient temperature of surroundings; a prior charging cycle of the battery pack (102); a prior discharging cycle of the battery pack (102); a state of charge of the battery pack (102); and a degradation status of the battery pack (102).
6. A fast-charging system (1 18) for a battery pack (102), the fast-charging system (1 18) comprising: a battery monitoring system (BMS) (112) communicably coupled to one or more cells of the battery pack (102) and adapted to monitor one or more battery related parameters (114) of the battery pack (102); a thermal system (100) comprising: a pump (104) mounted onto a battery casing (106) of the battery pack (102); a plurality of tubes (108) fluidly coupled to the pump (104) and mounted onto the battery casing (106) of the battery pack (102), the plurality of tubes (108) being adapted to circulate a thermal fluid for maintaining a fast-charging temperature of the battery pack (102), upon actuation of the pump (104); and a control unit (110) communicably coupled to the pump (104) and to the BMS (112), the BMS (112) being communicably coupled to the battery pack (102); the control unit (110) adapted to control actuation of the pump (104) based on the one or more battery related parameters (114) for circulating the thermal fluid within the plurality of tubes (108) to maintain the fast-charging temperature of the battery pack (102), during fast-charging of the battery pack (102); and a current supply device (120) communicably coupled to the BMS (112) and adapted to be coupled to the battery pack (102), the current supply device (120) configured to supply current to the battery pack (102) for fastcharging the battery pack (102), based on the one or more battery related parameters determined by the BMS (112). The fast-charging system (1 18) as claimed in claim 6, wherein the plurality of tubes (108) are adapted to surround the battery casing (106) of the battery pack (102), thereby facilitating circulation of the thermal fluid around the battery pack (102) uniformly. The fast-charging system (118) as claimed in claim 6, wherein at least one tube (108a) of the plurality of tubes (108) is inserted into the battery casing (106) of the battery pack (102) for monitoring temperature of the battery pack (102). The fast-charging system (118) as claimed in claim 6 comprises an indication unit (116) mounted onto the battery casing (106) for indicating temperature of the battery pack (102), the indication unit (116) being an audio-visual indication unit. The fast-charging system (118) as claimed in claim 6, wherein the one or more battery related parameters (114) comprises: a temperature of the battery pack (102); an ambient temperature of surroundings; a prior charging cycle of the battery pack (102); a prior discharging cycle of the battery pack (102); a state of charge of the battery pack (102); and a degradation status of the battery pack (102). The fast-charging system (118) as claimed in claim 6, wherein the BMS (112) is adapted to identify the battery pack (102) based on an identification number provided on the battery pack (102), the BMS (112) upon identification is configured to retrieve the one or more battery related parameters of the battery pack (104). The fast-charging system (118) as claimed in claim 6, wherein the BMS (112) is adapted to compute current required to be supplied from the current supply device (120) to the battery pack (102), based on the one or more battery related parameters (114) of the battery pack (102). The fast-charging system (118) as claimed in claim 6, wherein the BMS (112) is configured to compute a fast-charging temperature of the battery pack (102) based on current to be supplied and the one or more battery related parameters (1 14). The fast-charging system (118) as claimed in claim 6, wherein the BMS (112) is configured to compute current required to be supplied from the current supply device (120) to the battery pack (102) and the fast-charging temperature, based on an input received from a user pertaining to a required fast charge range and a charging time through an input device (124). A method for fast-charging a battery pack (102), the method comprising: identifying, by a BMS (112), the battery pack (102) to be charged, through an identification number provided to the battery pack (102); retrieving, by the BMS (112), one or more battery related parameters (114) of the battery pack (102); computing, by the BMS (112), current to be supplied from a current supply device (120) to the battery pack (102) for fast-charging the battery pack (102) based on the one or more battery related parameters (114); computing, by the BMS (112), a fast-charging temperature of the battery pack (102) based on the current to be supplied and the one or more battery related parameters (1 14); actuating, by a control unit (110) communicably coupled to the BMS (112), a pump (104) of a thermal system (100), wherein actuation of the pump (104) circulates a thermal fluid within a plurality of tubes (108) mounted onto a battery casing (106) of the battery pack (102) for maintaining the fast-charging temperature of the battery pack (102); and operating, by the BMS (112), the current supply device (120) for supplying the computed current to the battery pack (102) for fast-charging the battery pack (102).
EP23845846.7A 2022-07-29 2023-03-08 Thermal system for battery pack, fast-charging system and method of fast-charging thereof Pending EP4562712A1 (en)

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PCT/IN2023/050220 WO2024023830A1 (en) 2022-07-29 2023-03-08 Thermal system for battery pack, fast-charging system and method of fast-charging thereof

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