EV Battery Repair Innovations

A method to improve battery cell performance and longevity by dynamically adjusting charging and discharging current limits based on cell temperature and state. The method involves monitoring the actual cell temperature and current during operation. A thermal model of the cell calculates the internal temperature based on the external temperature and current. If the calculated internal temperature is higher than the external temperature, it indicates self-heating. In that case, the method reduces the current limits to prevent overheating. This avoids abrupt degradation and potential cell failure from excessive heating.

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Adaptive cooling management for traction batteries in electric vehicles to improve thermal performance as batteries age. It uses artificial intelligence to dynamically adjust cooling flow rates based on battery state. Sensors monitor battery parameters like voltage, temp, resistance. An AI model analyzes this data to determine the battery's operating state. It calculates a correction factor to add/multiply with the target flow rate set by the control module. This factor compensates for aging effects like swelling cells that narrow flow channels. The AI-calculated factor is sent to the control module to adjust cooling flow rates for the specific battery state.

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Battery pack case for electric vehicles that allows easier and cheaper replacement of worn or damaged parts. The case uses a bolt and nut coupling instead of welding. The bolt attaches to the vehicle frame, with a first nut tightening onto it and a second nut tightening onto the first nut. This provides a secure connection without welding. When the battery pack is repeatedly attached and detached, only the nuts may wear out or get damaged. By avoiding welding, these nuts can be easily replaced instead of the entire frame, reducing maintenance cost.

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An efficient way to refurbish, repair or test used battery packs from electric vehicles. The method involves removing the battery pack from the vehicle, testing and identifying any bad or failing batteries, and replacing them with similar batteries that have compatible electrical characteristics. By replacing only the specific failing batteries instead of the entire pack, the cost and waste associated with battery pack replacements can be reduced.

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Method and device for optimized charging and discharging of battery packs to improve overall pack life by equalizing the degradation of individual modules. It calculates the degradation state of each module based on charge/discharge status, and if any module's degradation exceeds a threshold, it determines an optimal charge/discharge rate for all modules based on temperature differences between modules. This command set is then used to control charging and discharging of all modules to balance degradation and prevent uneven aging.

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Protective battery management system for lithium batteries that uses predictive analytics to prevent overheating, excessive humidity, and high currents that can damage batteries. The system has a server, mobile terminal, and balancing device connected in pairs. The balancing device acquires battery pack data and a neural network in the server predicts temperature, humidity, and current. Analyzing the predictions, the server sends instructions to the balancing device to adjust battery state to prevent excessive temperatures, humidity, and currents that accelerate aging or damage batteries. This proactive monitoring and regulation improves battery protection and longevity.

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Method to accurately identify low voltage defects in lithium secondary batteries after formation by accounting for temperature exposure during transport and storage. The method involves measuring the primary voltage of a battery after formation, then measuring the secondary voltage after transport. The secondary voltage is corrected based on the temperature exposure during transport. If the corrected secondary voltage is significantly lower than the primary voltage, it indicates a low voltage defect. This prevents false positives due to normal batteries experiencing higher voltage drops at higher temperatures.

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Battery control device for electric vehicles that adapts charging limits based on battery condition to prevent damage and improve charging efficiency as batteries age. The device estimates the upper voltage limit for charging a battery based on its internal deterioration state. This allows charging more power without risking overcharge as metal ion precipitation becomes less likely. The device stores upper voltage limits for each temperature, and updates them as batteries degrade. This enables charging optimization that compensates for battery degradation without risking overcharge.

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Recovering the capacity of lithium batteries that have degenerated during cycling by heat treatment. The method involves subjecting a lithium battery cell with at least 5% capacity loss to a high temperature treatment of 60-100°C for 1-6 hours in a fully discharged state. This reversibly activates lithium plating on the negative electrode to prevent further capacity loss. The heat treatment should be outside the range where it affects other battery components.

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Method for optimizing the operation of a battery pack in an electric vehicle to extend battery life and efficiency. The method involves preprocessing battery data, extracting statistical features, generating thermal models, predicting SOH/SOC, balancing cell charges, and optimizing current profiles. It uses machine learning to analyze historical battery data and predict degradation, charge balance, and optimal charging/discharging currents to maximize battery life and performance.

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Monitoring and controlling rechargeable batteries to improve lifespan and prevent failures. The method involves individual battery monitoring using onboard sensors to measure voltage, current, and temperature. This allows tracking state of charge, state of health, estimated charge/discharge times, and replacement times. Deviations from normal ranges trigger alerts and actions like balancing energy flow or reducing cycles. This real-time per-cell monitoring enables proactive maintenance and avoids premature battery replacement.

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Real-time monitoring and management system for electric vehicle batteries that continuously monitors voltage, current, and temperature of individual cells during charging and discharging to detect issues and prevent failures. The system uses monitoring units connected to the cells that transmit data to an acquisition module. If limits are exceeded, it alarms the management module which activates a mechanism to adjust the cell operating state. This allows proactive intervention to mitigate cell issues before they become critical.

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Active battery life control for electric vehicles to extend battery lifespan by dynamically adjusting charging and discharging strategies based on the battery state. The method involves building a battery life model using test data, then calculating a remaining life estimate during operation. This estimate is used to optimize charging/discharging parameters to slow down the battery aging rate.

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A battery management system (BMS) technique for extending the life of power batteries in electric vehicles by adaptively adjusting battery usage parameters based on mileage, vehicle type, and environmental conditions. The BMS monitors the vehicle's odometer in real time and optimizes charging/discharging logic as the battery ages. It also modifies parameters like SOC range, charging cutoff, and current limit based on factors like temperature and vehicle type. This adaptive management improves battery life by accounting for actual usage instead of just SOH.

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Balancing charging and discharging individual batteries in an electric vehicle's battery pack to improve pack performance and lifespan. The balancing is done by selectively charging or discharging cells to match the charge levels of other cells. This prevents overcharging of some cells while undercharging others, which can degrade pack performance. The balancing is done using a maintenance device that can independently charge/discharge cells in the pack.

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Reducing mechanical degradation of batteries to improve their performance. This involves preventing mechanical issues that can impact battery life, such as vibration, shock, and bending. Techniques to achieve this could include: using enclosures to protect the battery from external forces, designing the battery shape to better withstand handling and transport, improving battery packaging and mounting methods to reduce vibration and shock, and implementing battery management systems that monitor and mitigate mechanical stress on the cells.

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Low-temperature lithium battery management system for electric forklifts that improves battery performance and longevity when operating in cold environments. The system uses a control unit, display, acquisition, evaluation, temperature control, charge/discharge rate, and fault units. It predicts battery health, adjusts charge/discharge rates, and heats the battery when needed. The acquisition unit collects data like impedance, temperature, voltage, current. The evaluation unit analyzes the data to assess battery condition. The temperature control unit heats the battery if needed. The charge/discharge rate control unit adjusts rates based on battery health. The fault unit disconnects the battery if issues are detected. The control unit coordinates all functions based on the acquired battery data.

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Accurately estimating the available capacity and remaining capacity of each battery cell in a vehicle's pack to improve battery health monitoring. The method involves waking the battery during certain power-on cycles to collect temperature and state of charge data. If the temperature difference between cycles meets a condition, it estimates cell capacities based on previous cycle data to account for factors like charge, discharge, temperature, and self-discharge. This ensures consistent parameter acquisition for capacity estimation and increases accuracy by considering all relevant factors.

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Energy management method for composite energy storage electric vehicles that extends battery life by estimating aging state and dynamically adjusting energy distribution based on highest battery temperature during charging. As batteries age, their internal resistance increases, leading to higher temperatures during charging. By tracking the temperature rise, the method adjusts power output from batteries versus supercapacitors to slow aging. It also recovers braking energy in the composite system to charge batteries and mitigate power demand spikes.

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Active control method for power battery thermal management systems that improves efficiency and life by continuously stabilizing battery temperature instead of passive on/off cycling. The method involves monitoring battery temperature, heat generation, and natural dissipation. If heat generation exceeds natural dissipation, the management system is activated to cool the battery. If generation is less, it is deactivated. This proactive approach prevents excessive heating and overcooling compared to passive on/off control.

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