DESC:METHOD AND SYSTEM FOR CONTROLLING ACTIVE COOLING CIRCUIT OF SWAPPABLE BATTERY PACK
CROSS REFERENCE TO RELATED APPLICTIONS
The present application claims priority from Indian Provisional Patent Application No. 202321090115 filed on 30/12/2023, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to active cooling of swappable battery packs. Particularly, the present disclosure relates to a system for controlling an active cooling circuit for cooling the swappable battery pack. Furthermore, the present disclosure relates to a method of controlling an active cooling circuit for cooling a swappable battery pack.
BACKGROUND
Recently, there has been a rapid development in battery packs because of their use as clean energy storage solution for various uses ranging from domestic use to transportation use. The battery pack comprises a set of any number of identical batteries or individual battery cells. The battery cells are assembled as cell arrays and multiple cell arrays are combined to form the battery packs.
Each battery pack comprises a plurality of cells and cell holders to secure the plurality of cells. These battery cells are electrically connected to form cell arrays and multiple cell arrays can be stacked together to form the battery pack, being used as a single unit for meeting high voltage and current requirements. However, the battery pack generates a large amount of heat during the charging and discharging process. If heat generated during the charging and discharging process is not effectively eliminated, heat accumulation may occur inside the battery, which results in accelerated deterioration of the battery cells. Moreover, in some conditions such heat accumulation may even lead to hotspots causing thermal runaway which would permanently damage the battery pack. Furthermore, the thermal runaway may lead to fire and/or explosion causing safety risks.
Generally, to eliminate the heat and prevent resultant damages, a cooling jacket is placed on the outer surfaces such as the casing of the battery pack. However, such a cooling structure can only extract heat from the outer portions of the battery pack, leaving the inner portions of the battery pack at a higher temperature. Thus, a temperature gradient is formed between the inner and outer portion of the battery pack which leads to poor cell performance and higher degradation rate. To reduce the temperature gradient and extract heat from the inner portions of the battery pack, a submerged cooling technique is used wherein all the battery cells of the battery pack are submerged in a coolant. The battery pack with coolant-submerged battery cells have a lower temperature gradient between the outer and inner portions of the battery pack. However, the use of such a cooling technique leads to an increase in the weight of the battery pack. Furthermore, the size and cost of the battery pack is also increased significantly. Moreover, such cooling techniques add unnecessary bulk to the already bulky battery pack. Furthermore, the added weight and size affects the performance of the battery pack in mobile application such as electric vehicles.
Moreover, the above-described cooling techniques are not feasible for implementation in the swappable battery packs, as the battery pack is often required to be removed from the electric vehicle. The existing air-cooling mechanisms are inefficient to meet the higher cooling requirement of the swappable battery packs. The cooling arrangements have a slower rate of transfer of heat leading to inefficient cooling of the battery packs. Furthermore, the liquid cooling-based system for swappable batteries only allows cooling on the outer surface of the battery packs leading to higher temperatures inside the battery packs and the techniques lack efficient removal of the heat from the inner portions of the battery packs. Moreover, it is difficult to provide active cooling for the swappable battery packs as the coolant flow path between the battery and the coolant supply unit breaks during the swapping of the battery pack. Also, existing cooling techniques are inadequate for battery packs with higher thermal demands, as the cooling systems lack the adaptability to provide enhanced cooling for such battery packs. This limitation results in inefficient heat dissipation, potentially leading to thermal imbalances or overheating. Furthermore, the existing cooling systems lacked real-time adaptability, often leading to undercooling or overcooling, which may reduce the battery efficiency, lifespan, and performance. Furthermore, due to frequent replacement of the battery packs, the coolant present inside the battery pack may leak during the battery swapping process.
Therefore, there exists a need for an improved cooling mechanism that overcomes the one or more problems associated as set forth above.
SUMMARY
The object of the present disclosure is to provide a system for controlling an active cooling circuit for cooling the swappable battery pack.
Another object of the present disclosure is to provide a method for controlling an active cooling circuit for cooling the swappable battery pack.
In accordance with first aspect of the present disclosure, there is provided a system for controlling an active cooling circuit for cooling a swappable battery pack. The system comprises a sensing unit configured to sense at least one coolant flow parameter, at least one valve coupled with an inlet and an outlet of a coolant flow path of the swappable battery pack, a control unit communicably coupled to the sensing unit and the at least one valve. The control unit is configured to determine at least one coolant flow parameter, a thermal load of the swappable battery pack and control operation of the at least one valve to adjust the at least one coolant flow parameter based on the thermal load of the swappable battery pack.
The present disclosure discloses a system for controlling an active cooling circuit for the swappable battery pack. The system as disclosed by the present disclosure is advantageous in terms of providing precise control for the active cooling circuit in swappable battery packs. Beneficially, the system monitors the coolant flow parameters and ensures precise thermal management of the swappable battery pack. Beneficially, the system incorporates the active valve control to enable the dynamic adjustment of coolant flow based on real-time thermal load, which optimizes cooling efficiency. Furthermore, the system advantageously allows adaptive regulation of coolant flow based on the thermal load of the swappable battery pack, thereby optimizes energy consumption and preventing undercooling or overcooling. Moreover, the system minimizes energy consumption by cooling the particular battery packs which are required to be cooled. In other words, the coolant flows only through particular battery packs which are required to be cooled, thereby minimizing energy consumption required for the flow of coolant through the active cooling circuit. Additionally, the system promotes uniform temperature distribution across the battery packs, which extends the battery lifespan and improves safety by mitigating risks associated with thermal runaway. Beneficially, the system of the present disclosure is capable of being implemented in a commercial battery swapping station, a domestic home inverter with swappable battery packs, and/or an electric vehicle.
In accordance with second aspect of the present disclosure, there is provided a method of controlling an active cooling circuit for cooling a swappable battery pack. The method comprises determining at least one coolant flow parameter, determining a thermal load of the swappable battery pack and controlling operation of the at least one valve to adjust the at least one coolant flow parameter based on the thermal load of the swappable battery pack.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 illustrates a block diagram of a system for controlling active cooling circuit of swappable battery pack, in accordance with an aspect of the present disclosure.
FIG. 2 illustrates a flow chart of a method for controlling active cooling circuit of swappable battery pack, in accordance with another aspect of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.

DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a system for controlling an active cooling circuit for cooling a swappable battery pack and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings and which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the terms “electric vehicle”, “EV”, and “EVs” are used interchangeably and refer to any vehicle having stored electrical energy, including the vehicle capable of being charged from an external electrical power source. This may include vehicles having batteries which are exclusively charged from an external power source, as well as hybrid-vehicles which may include batteries capable of being at least partially recharged via an external power source. Additionally, it is to be understood that the ‘electric vehicle’ as used herein includes electric two-wheeler, electric three-wheeler, electric four-wheeler, electric pickup trucks, electric trucks and so forth.
As used herein, the term “active cooling circuit” refers to a system designed to regulate the temperature of a device or component, such as a swappable battery pack, through the circulation of a coolant medium. The circuit actively utilizes components such as pumps, valves, heat exchangers, and sensors to facilitate and control the movement and exchange of the coolant. The active cooling circuit enables precise thermal management by actively responding to variations in thermal load which ensures the device or component operates within a predefined temperature range.
As used herein, the terms “swappable battery pack” and “battery pack” refers to a modular energy storage unit which is designed for easy removal and replacement in an electrical system or vehicle, without requiring permanent disassembly or specialized tools. The swappable battery pack typically includes a housing that encases one or more rechargeable battery packs, along with connectors and interfaces for electrical coupling, mechanical attachment, and thermal management integration. The swappable battery packs are configured to maintain operational functionality during exchange processes and is compatible with external systems, such as cooling circuits, charging infrastructure, or control units, to ensure seamless performance and thermal regulation during operation.
As used herein, the term “sensing unit” refers to a component or a combination of components configured to detect and measure one or more parameters related to the coolant flow or the thermal state of the battery pack and the system. The sensing unit may include, but is not limited to, flow sensors, temperature sensors, pressure sensors, or any other sensors capable of generating signals indicative of coolant flow rate, coolant temperature, system pressure, or other relevant coolant flow characteristics.
As used herein, the term “at least one coolant flow parameter” and “coolant flow parameter” are used interchangeably and refer to any measurable characteristic or attribute of the coolant flow within the active cooling circuit that is relevant for assessing and managing the thermal performance of the swappable battery pack. The at least one coolant flow parameter may include, but is not limited to, coolant flow rate, pressure, temperature, viscosity, density, or thermal conductivity. These parameters serve as input variables for the system to monitor and adjust the cooling process effectively, ensures optimal thermal regulation and performance of the swappable battery pack.
As used herein, the term “at least one valve” refers to a component or a set of components configured to regulate, control, or restrict the flow of coolant within the cooling circuit. The at least one valve may include, but is not limited to, proportional valves or other types of flow-controlling devices. The valve may operate in response to signals received from a control unit and can be positioned along the coolant flow path, including at the inlet and/or outlet of the swappable battery pack, to modulate coolant flow based on specific parameters such as temperature, pressure, or flow rate.
As used herein, the term “coolant flow path” refers to a predefined conduit or network of channels designed to facilitate the controlled movement of a coolant fluid through the active cooling system of a swappable battery pack. The coolant flow path encompasses components such as inlet and outlet passages, internal conduits within the battery pack, connecting pipes, and any intermediate elements that guide the coolant from its entry point, through the battery pack's cooling structure, to the exit point. The coolant flow path is configured to enable efficient heat transfer between the coolant and the battery cells, ensuring effective thermal regulation of the battery pack during operation.
As used herein, the term “control unit” refers to a hardware and/or software-based component configured to receive and process data from a sensing unit and control one or more operational elements of the active cooling circuit. The control unit is responsible for determining thermal load parameters, analysing the data from the sensing unit regarding coolant flow, and generating commands to adjust the operation of one or more valves or other control mechanisms in the coolant flow path. The control unit may include a processor, memory, and communication interfaces that allow for the real-time monitoring and regulation of coolant flow parameters, ensuring efficient cooling of the swappable battery pack based on its thermal load. Optionally, the control unit includes, but is not limited to, a microprocessor, a micro-controller, a complex instruction set computing (CISC) microprocessor, a reduced instruction set (RISC) microprocessor, a very long instruction word (VLIW) microprocessor, or any other type of processing circuit. Furthermore, the term “processor” may refer to one or more individual processors, processing devices and various elements associated with a processing device that may be shared by other processing devices. Furthermore, the control unit may comprise ARM Cortex-M series processors, such as the Cortex-M4 or Cortex-M7, or any similar processor designed to handle real-time tasks with high performance and low power consumption. Furthermore, the control unit may comprise custom and/or proprietary processors.
As used herein, the term “communicably coupled” refers to a bi-directional connection between the various components of the system. The bi-directional connection between the various components of the system enables exchange of data between two or more components of the system. Similarly, bi-directional connection between the system and other elements/modules enables exchange of data between system and the other elements/modules.
As used herein, the term “thermal load” refers to the amount of heat generated by the swappable battery pack during its operation, which must be dissipated to maintain the battery pack within a specified temperature range. The thermal load is influenced by factors such as the current flow through the battery cells, the rate of energy discharge or charge, ambient temperature conditions, and the internal resistance of the battery. The thermal load represents the energy input required to maintain the optimal performance of the battery and prevent overheating.
As used herein, the term “coolant flow rate sensor” refers to a sensing device or component designed to measure the rate at which coolant flows through a cooling circuit, specifically within the active cooling system for the swappable battery pack. The sensor typically detects the velocity or volume of the coolant moving through the cooling path and converts this information into an electrical or digital signal. The signals are then used by the control unit to monitor and adjust the cooling parameters, which ensures optimal thermal management of the battery pack.
As used herein, the term “coolant pressure sensor” refers to a device or component configured to measure the pressure of the coolant fluid within the cooling circuit of a system designed for cooling a swappable battery pack. The sensor is capable of detecting variations in coolant pressure and provides the real-time data to the control unit. The data is essential for monitoring the performance of the cooling system, ensuring proper coolant flow, and maintaining optimal thermal management of the battery pack. The sensor may be positioned at strategic points within the coolant flow path, such as the inlet, outlet, or other critical sections, to accurately assess the pressure levels and enable the control unit to adjust the operation of valves or other components accordingly.
As used herein, the term “coolant temperature sensor” refers to a device or component configured to detect and measure the temperature of the coolant circulating through the cooling system of a swappable battery pack. The sensor generates an output signal corresponding to the temperature of the coolant, which is then used by the control unit to assess the thermal state of the battery pack. The coolant temperature sensor may utilize various temperature sensing technologies, such as thermocouples, thermistors, or resistance temperature detectors (RTDs), and is typically integrated into the coolant flow path to provide real-time temperature data for optimizing the cooling performance and ensuring the battery pack operates within safe and efficient thermal limits.
As used herein, the term “pressure pump” refers to a mechanical device configured to increase the pressure of a coolant fluid within the cooling circuit. The pressure pump is responsible for facilitating the movement of the coolant through the coolant flow path, ensuring steady circulation and constant flow rate to effectively manage heat dissipation from the swappable battery pack.
As used herein, the term “battery management system” and “BMS” are used interchangeably and refer to an electronic control system configured to monitor, manage, and optimize the performance, safety, and lifecycle of a swappable battery pack. The BMS is designed to communicate with the cooling system to assess battery parameters such as temperature, state of charge, and state of health. Furthermore, the BMS provides real-time data to the control unit, enabling efficient thermal management by dynamically adjusting cooling operations to maintain optimal battery operating conditions during charging, discharging, and swapping processes. Additionally, the BMS provides protection by controlling charging and discharging processes, detecting and responding to faults, balancing cell performance, and managing thermal conditions. The BMS may also include communication interfaces to provide real-time data and control signals for system optimization and fault recovery.
As used herein, the term “at least one operational parameter” refers to a measurable variable or condition that influences or governs the functioning, performance, or behaviour of the swappable battery pack. The at least one operational parameter may include, but is not limited to, parameters such as rate of charge, rate of discharge, voltage, current, temperature, state of charge, state of health, thermal load. These parameters are used to monitor, control, or optimize the performance, safety, and efficiency of the battery pack during its operation.
As used herein, the term “at least one actuator” refers to a mechanical, electrical, or electromechanical device configured to perform a specific action in response to a control signal, typically by altering the position or state of a component in the system. The at least one actuator may be used to manipulate the at least one valve to regulate the coolant flow. The actuator can be, but is not limited to, a motor, solenoid, pneumatic or hydraulic piston, servo motor and/or stepper motor, which operates based on signals received from the control unit to adjust or control the movement of the valve or other components within the cooling system. The actuator enables precise and responsive control of the cooling parameters, facilitating optimal thermal management for the battery pack.
As used herein, the term “operatively coupled” refers to the functional connection or relationship between two components or devices, such that they are capable of working together to achieve a specific function or result. Moreover, the mechanism or structure of the connection, but emphasizes that the components are arranged to work together effectively within the system as intended.
As used herein, the term “feedback loop” refers to a system mechanism wherein the output or result of a process is continuously monitored and used to adjust or regulate the input or operating conditions of that process. Specifically, the feedback loop involves the sensing unit for monitoring the coolant flow parameters, such as temperature or flow rate, and transmitting the data to the control unit. Based on the information, the control unit makes real-time adjustments to the operation of valves in the cooling circuit, modifying coolant flow to manage the thermal load of the swappable battery pack.
As used herein, the term “input unit” refers to a component or module configured to receive inputs, signals, or commands from a user or an external system. The input unit can include various interfaces such as physical buttons, touchscreens, sensors, wireless communication modules, or other input devices. The input unit is designed to accept a swap command or other related instructions, facilitating user interaction and enabling the system to execute corresponding operations effectively.
As used herein, the term “real-time thermal load” refers to the instantaneous or current rate of heat generation or dissipation within the battery pack, determined by factors such as the power output, charge/discharge cycles, environmental conditions, and operational state of the battery. The thermal load is continuously monitored and assessed to accurately reflect the immediate cooling needs of the battery pack at any given moment, enabling dynamic adjustment of the coolant flow parameters to maintain optimal temperature control and prevent overheating.
As used herein, the term “user” refers to an owner of the swappable battery pack and/or a technician and/or a service personnel and/or a service manager.
As used herein, the term “swap command” refers to a signal or instruction issued by a user that initiates the process of replacing one battery pack with another within a vehicle or energy storage system. This command can be triggered manually by the user or automatically based on system conditions, such as the battery pack reaching a predetermined state of charge, thermal condition, or operational threshold.
Figure 1, in accordance with an embodiment describes a system 100 for controlling an active cooling circuit for cooling a swappable battery pack 102. The system 100 comprises a sensing unit 104 configured to sense at least one coolant flow parameter, at least one valve 106 coupled with an inlet and an outlet of a coolant flow path of the swappable battery pack 102, a control unit 108 communicably coupled to the sensing unit 104 and the at least one valve 106. The control unit 108 is configured to determine at least one coolant flow parameter, a thermal load of the swappable battery pack 102 and control operation of the at least one valve 106 to adjust the at least one coolant flow parameter based on the thermal load of the swappable battery pack 102.
The present disclosure discloses the system 100 for controlling the active cooling circuit for cooling the swappable battery pack 102. The system 100 as disclosed by present disclosure is advantageous in terms of providing significant advancements in the efficient thermal management of the swappable battery pack 102 which ensures improved performance, safety, and reliability. Beneficially, the sensing unit 104 as disclosed by present disclosure is advantageously monitors the coolant flow parameters which enables precise and real-time assessment of cooling requirements of the swappable battery pack 102. Furthermore, the control of at least one valve 106 allows for adaptive regulation of coolant flow based on the thermal load of the swappable battery pack 102, thereby optimizes the energy consumption and preventing undercooling or overcooling. Beneficially, the connectivity of the system 100 with a battery management system 112 enhances the functionality and ensures the thermal load is accurately determined and managed. Furthermore, a pressure pump 110 as disclosed by present disclosure significantly ensures the consistent and adequate coolant flow, thereby improves the cooling efficiency. Moreover, the system 100 employs a feedback loop for continuous real-time adjustments, ensures optimal thermal management under dynamic conditions. Beneficially, the system 100 extends the lifespan of the swappable battery pack 102 and reduces the risk of thermal runaway which significantly ensures the uniform temperature distribution across each cell of the swappable battery pack 102. Furthermore, the integration of the at least one actuator 114 for precise valve operation and user-friendly features like swap confirmations makes the system 100 robust.
In an embodiment, the sensing unit 104 comprises at least one of a coolant flow rate sensor, a coolant pressure sensor and a coolant temperature sensor. The coolant flow rate sensor may be configured to measure the flow rate of coolant circulating within the coolant flow path of the active cooling circuit, which enables the system 100 to monitor and adjust the flow dynamically. Furthermore, the coolant pressure sensor may be configured to detect the pressure of the coolant and provides critical data to ensure optimal flow conditions and prevent pressure-related inefficiencies or failures. Furthermore, the coolant temperature sensor measures the temperature of the coolant, ensures that the cooling circuit operates within the desired thermal parameters to maintain the swappable battery pack 102 at an optimal operating temperature. Beneficially, the coolant flow rate sensor, the coolant pressure sensor and the coolant temperature sensor collectively provide the real-time data to the control unit 108 on coolant flow parameters which significantly enables precise control of the active cooling circuit and ensures efficient thermal management of the swappable battery pack 102.
In an embodiment, the at least one coolant flow parameter comprises a coolant flow rate, a coolant pressure and a coolant temperature. The sensing unit 104 may be configured to sense each of the at least one coolant flow parameter in real time and transmit the data to the control unit 108. Based on the sensed coolant flow rate, the control unit 108 may determine if the flow is sufficient to dissipate the heat generated by the swappable battery pack 102 under varying operational conditions. Similarly, by monitoring the coolant pressure, the system 100 may identify potential blockages or malfunctions in the coolant flow path. Additionally, the temperature of the coolant is monitored to ensure that the temperature remains within an optimal range to prevent undercooling and overcooling of the battery pack 102.
In an embodiment, the system 100 comprises a pressure pump 110 configured to generate flow and pressure of the coolant in the active cooling circuit. The pressure pump 110 ensures consistent circulation of coolant through the coolant flow path, including the inlet and outlet coupled to the swappable battery pack 102. Beneficially, the pressure pump 110 ensures effective heat transfer from the swappable battery pack 102, thereby maintains optimal operating temperatures. Also, the pressure pump 110 enhances the cooling ability of the system 100 by maintaining adequate coolant pressure and provides the efficient cooling for the swappable battery pack 102.
In an embodiment, the control unit 108 is communicably coupled to a battery management system 112 of the swappable battery pack 102 to receive at least one operational parameter of the swappable battery pack 102. The operational parameters may include, but are not limited to, the rate of charge, rate of discharge, voltage, current, temperature, state of charge, state of health, thermal load. The control unit 108 may be configured to receive at least one operational parameter from the BMS 112, which monitors and manages the overall battery performance. By receiving the at least one operational parameter, the control unit 108 may be capable to accurately determine the thermal load of the swappable battery pack 102 during operation. Beneficially, the at least one operational parameter helps the control unit 108 to dynamically adjust the operation of the active cooling circuit. The dynamic adjustment includes the control of the at least one valve 106 which helps to regulate coolant flow parameters, to maintain the optimal temperature conditions for the swappable battery pack 102.
In an embodiment, the control unit 108 is configured to determine the thermal load of the swappable battery pack 102 based on the at least one operational parameter received from the battery management system 112 of the swappable battery pack 102. The determination of the thermal load allows the control unit 108 to assess the cooling requirements of the swappable battery pack 102 in real time, thereby ensures that the active cooling circuit operates efficiently and maintains optimal battery performance. Beneficially, by leveraging the data provided by the battery management system 112, the control unit 108 significantly enhances the precision and adaptability of the active cooling system which contributes to improved thermal management, extended battery life, and overall system safety.
In an embodiment, the system 100 comprises at least one actuator 114 operatively coupled with the respective valve to control the operation of the at least one valve 106, based on an instruction received from the control unit 108. The at least one actuator 114 may be configured to execute precise mechanical operations to control the position and operation of the at least one valve 106 based on instructions received from the control unit 108. The control unit 108 continuously monitors at least one coolant flow parameter, such as flow rate, pressure, or temperature, and determines the required adjustments to the at least one valve 106 for optimal thermal management of the swappable battery pack 102. Upon receiving the control signals from the control unit 108, the at least one actuator 114 adjusts the at least one valve 106 to regulate the flow of coolant in real time, thereby ensures efficient cooling based on the thermal load of the swappable battery pack 102.
In an embodiment, the at least one actuator 114 may comprise a servo motor. Beneficially, the servo motor may be configured to precisely control the opening and closing of the at least one valve 106. It is to be understood that the servo motor may be controlled by the control unit 108 to operate the at least one valve 106.
In an embodiment, the control unit 108 is configured to employ a feedback loop to re-adjust the at least one coolant flow parameter based on a real-time thermal load of the swappable battery pack 102 during cooling of the swappable battery pack 102. The feedback loop continuously monitors the real-time thermal load conditions of the swappable battery pack 102 using input data received from the sensing unit 104, which detects at least one coolant flow parameter such as coolant temperature, pressure, or flow rate. Based on this real-time data, the control unit 108 processes the information to identify deviations from the desired cooling conditions and recalibrates the operation of the at least one valve 106. Beneficially, the dynamic adjustment ensures that the coolant flow rate, pressure, and temperature are optimized to meet the cooling requirements of the swappable battery pack 102, thereby maintains a consistent thermal environment. Furthermore, the feedback loop mechanism significantly enhances the cooling precision and prevents thermal imbalance, thereby reduces the energy wastage by avoiding overcooling or undercooling.
In an embodiment, the system 100 comprises an input unit 116, wherein the input unit 116 is configured to receive a swap command from user for swapping of the swappable battery pack 112. The input unit 116 may be a physical button, a touchscreen panel, a mobile application, or a wireless communication module capable of receiving commands via Bluetooth, Wi-Fi, or other communication protocols. Upon receiving the swap command, the input unit 116 communicates the instruction to the control unit 108. The control unit 108 processes the command and subsequently initiates actions necessary for the safe and efficient swapping of the swappable battery pack 102.
In an embodiment, the control unit 108 is configured to control operation of the at least one valve 106 to stop the flow of coolant in the coolant flow path of the swappable battery pack 102, upon receiving the swap command from the user and generate a swap confirmation once the coolant is emptied out of the coolant flow path of the swappable battery pack 102. In the system 100, the control unit 108 may be communicably coupled to the at least one valve 106 which further connected to the coolant flow path of the swappable battery pack 102. Upon receiving the swap command through the input unit 116, the control unit 108 may be configured to control the operation of the at least one valve 106 to stop the flow of coolant within the coolant flow path. The closing of the at least one valve 106 ensures that the swappable battery pack 102 may be isolated from the active cooling circuit, which prevents the coolant spillage and maintains the integrity of the system 100 during the swapping process. Additionally, the control unit 108 may further configured to monitor the state of the coolant flow path and determine when the coolant is completely emptied out. Once the coolant is fully drained, the control unit 108 generates the swap confirmation signal, indicating that the swappable battery pack 102 is ready for safe removal and replacement.
In an exemplary embodiment, the system 100 for controlling the active cooling circuit for the swappable battery pack 102 operates when the temperature of the swappable battery pack 102 higher than the optimum operational threshold, due to fast charging or high-power delivery, indicating higher thermal load. Due to which, the system 100 dynamically increases the cooling capacity to maintain optimal operating conditions. The sensing unit 104, which includes sensors such as the coolant flow rate sensor, the coolant pressure sensor and the coolant temperature sensor, detects the elevated temperature of the swappable battery pack and the coolant. Based on the data from sensing unit 104, the control unit 108 calculates the thermal load and determines the need for increased cooling. Consequently, the system 100 adjusts the operation of the at least one valve 106 to ensure the adequate flow of coolant for the swappable battery pack 102. The system 100 employs the feedback loop to continuously monitor the temperature and coolant parameters, ensures the real-time adjustments for efficient cooling which ensures the battery pack 102 remains within a safe temperature range.
In an exemplary embodiment, the system 100 for controlling the active cooling circuit for the swappable battery pack 102 operates when the battery pack 102 is fully charged or fully discharged and no cooling is required. The control unit 108 continuously monitors the operational parameters of the swappable battery pack 102 and communicates with the battery management system 112. Upon detecting that the battery is fully charged, and the thermal load is within the predefined safe range, the control unit 108 determines that cooling is not required. In response, the control unit 108 signals the at least one valve 106 to close. The system 100 enters an idle state, continuously monitors the thermal condition of the swappable battery pack 102 to ensure no overheating occurs.
In an exemplary embodiment, the system 100 for controlling the active cooling circuit for the swappable battery pack 102 operates dynamically when the swappable battery pack 102 is in a normal operational state. During the normal condition, the control unit 108 receives the real-time data from the sensing unit 104, which monitors the coolant flow parameters such as temperature, pressure, and flow rate. Based on the data, the control unit 108 determines the thermal load of the battery pack 102 and calculates the required cooling level. To achieve optimal cooling, the control unit 108 sends precise instructions to the actuator 114, which adjusts the position of the at least one valve 106. In the normal state, the at least one valve 106 is partially opened or closed as required, allows just the right amount of coolant to flow through the coolant flow path. In the normal cooling scenario, the system 100 ensures sufficient heat dissipation without overcooling or wasting energy. Moreover, the feedback loop integrated into the system 100 continuously monitors the thermal load of the battery pack 102 and adjusts the at least one valve position in real-time to maintain the optimal operating temperature on the swappable battery pack 102.
In an exemplary embodiment, the system 100 for controlling the active cooling circuit for the swappable battery pack 102 operates when the swappable battery pack 102 is fully charged or fully discharged and the system 100 enters in a monitoring state to await the user-initiated swap command. Upon receiving the swap command through the input unit 116, the control unit 108 verifies the charging state of the battery pack 102 and initiates the coolant drainage process. The control unit 108 sends the signal to operate the at least one valve 106 and the associated actuator 114 to direct the coolant out of the coolant flow path of the swappable battery pack 102. The system 100 ensures complete drainage of coolant from the coolant flow path to prevent spillage or contamination during the swapping process of the battery pack 102. Once the coolant is fully drained, the control unit 108 generates the swap confirmation signal, indicating that the swappable battery pack 102 is ready for safe removal and replacement.
In an embodiment, the system 100 for controlling the active cooling circuit for cooling the swappable battery pack 102. The system 100 comprises the sensing unit 104 configured to sense the at least one coolant flow parameter, the at least one valve 106 coupled with the inlet and an outlet of the coolant flow path of the swappable battery pack 102, the control unit 108 communicably coupled to the sensing unit 104 and the at least one valve 106. The control unit 108 is configured to determine the at least one coolant flow parameter, the thermal load of the swappable battery pack 102 and the control operation of the at least one valve 106 to adjust the at least one coolant flow parameter based on the thermal load of the swappable battery pack 102. Furthermore, the sensing unit 104 comprises the at least one of the coolant flow rate sensor, the coolant pressure sensor and the coolant temperature sensor. Furthermore, the at least one coolant flow parameter comprises the coolant flow rate, the coolant pressure and the coolant temperature. Furthermore, the system 100 comprises the pressure pump 110 configured to generate the flow and the pressure of the coolant in the active cooling circuit. Furthermore, the control unit 108 is communicably coupled to the battery management system 112 of the swappable battery pack 102 to receive the at least one operational parameter of the swappable battery pack 102. Furthermore, the control unit 108 is configured to determine the thermal load of the swappable battery pack 102 based on the at least one operational parameter received from the battery management system 112 of the swappable battery pack 102. Furthermore, the system 100 comprises the at least one actuator 114 operatively coupled with the respective valve to control the operation of the at least one valve 106, based on the instruction received from the control unit 108. Furthermore, the control unit 108 is configured to employ the feedback loop to re-adjust the at least one coolant flow parameter based on a real-time thermal load of the swappable battery pack 102 during cooling of the swappable battery pack 102. Furthermore, the system 100 comprises the input unit 116, wherein the input unit 116 is configured to receive the swap command from user for swapping of the swappable battery pack 112. Furthermore, the control unit 108 is configured to control operation of the at least one valve 106 to stop the flow of coolant in the coolant flow path of the swappable battery pack 102 and generate the swap confirmation once the coolant is emptied out of the coolant flow path of the swappable battery pack 102.
Figure 2, describes a method 200 of controlling an active cooling circuit for cooling a swappable battery pack 102. The method 200 starts at step 202 and completes at step 206. At step 202, the method 200 comprises determining at least one coolant flow parameter. At step 204, the method 200 comprises determining a thermal load of the swappable battery pack 102. At step 206, the method 200 comprises generating a swap confirmation once the coolant is emptied out of the coolant flow path of the swappable battery pack 102.
In an embodiment, the method 200 further comprises receiving a swap command from a user, controlling operation of the at least one valve 106 to stop the flow of coolant in the coolant flow path of the swappable battery pack 102 upon receiving swap command from the user and generating a swap confirmation once the coolant is emptied out of the coolant flow path of the swappable battery pack 102. Beneficially, the method 200 significantly enhances the user experience by ensuring a seamless, efficient, and safe swapping process of swappable battery pack 102.
It would be appreciated that all the explanations and embodiments of the system 100 also applies mutatis-mutandis to the method 200.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combination of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non- exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:WE CLAIM:
1. A system (100) for controlling an active cooling circuit for cooling a swappable battery pack (102), wherein the system (100) comprises:
- a sensing unit (104) configured to sense at least one coolant flow parameter;
- at least one valve (106) coupled with an inlet and an outlet of a coolant flow path of the swappable battery pack (102);
- a control unit (108) communicably coupled to the sensing unit (104) and the at least one valve (106), wherein the control unit (108) is configured to:
- determine at least one coolant flow parameter;
- determine a thermal load of the swappable battery pack (102); and
- control operation of the at least one valve (106) to adjust the at least one coolant flow parameter based on the thermal load of the swappable battery pack (102).
2. The system (100) as claimed in claim 1, wherein the sensing unit (104) comprises at least one of: a coolant flow rate sensor, a coolant pressure sensor and a coolant temperature sensor.
3. The system (100) as claimed in claim 1, wherein the at least one coolant flow parameter comprises: a coolant flow rate, a coolant pressure and a coolant temperature.
4. The system (100) as claimed in claim 1, wherein the system (100) comprises a pressure pump (110) configured to generate flow and pressure of the coolant in the active cooling circuit.
5. The system (100) as claimed in claim 1, wherein the control unit (108) is communicably coupled to a battery management system (112) of the swappable battery pack (102) to receive at least one operational parameter of the swappable battery pack (102).
6. The system (100) as claimed in claim 5, wherein the control unit (108) is configured to determine the thermal load of the swappable battery pack (102) based on the at least one operational parameter received from the battery management system (112) of the swappable battery pack (102).
7. The system (100) as claimed in claim 1, wherein the system (100) comprises at least one actuator (114) operatively coupled with the respective valve to control the operation of the at least one valve (106), based on an instruction received from the control unit (108).
8. The system (100) as claimed in claim 1, wherein the control unit (108) is configured to employ a feedback loop to re-adjust the at least one coolant flow parameter based on a real-time thermal load of the swappable battery pack (102) during cooling of the swappable battery pack (102).
9. The system (100) as claimed in claim 1, wherein the system (100) comprises an input unit (116), wherein the input unit (116) is configured to receive a swap command from user for swapping of the swappable battery pack (102).
10. The system (100) as claimed in claim 9, wherein the control unit (108) is configured to:
- control operation of the at least one valve (106) to stop the flow of coolant in the coolant flow path of the swappable battery pack (102), upon receiving the swap command from the user; and
- generate a swap confirmation once the coolant is emptied out of the coolant flow path of the swappable battery pack (102).
11. A method (200) of controlling an active cooling circuit for cooling a swappable battery pack (102), wherein the method (200) comprises:
- determining at least one coolant flow parameter;
- determining a thermal load of the swappable battery pack (102); and
- controlling operation of the at least one valve (106) to adjust the at least one coolant flow parameter based on the thermal load of the swappable battery pack (102).
12. The method (200) as claimed in claim 11, wherein the method (200) further comprises:
- receiving a swap command from a user;
- controlling operation of the at least one valve (106) to stop the flow of coolant in the coolant flow path of the swappable battery pack (102) upon receiving swap command from the user; and
- generating a swap confirmation once the coolant is emptied out of the coolant flow path of the swappable battery pack (102).