Lithium-Ion Battery Temperature Sensing for EVs

Intelligent vehicle system that predicts and responds to thermal runaway events in vehicle batteries when parked in enclosed spaces. The system detects battery cell overheating and determines if the vehicle is parked in an enclosed area using sensors and vehicle data. If so, it alerts nearby people and first responders about the thermal event and provides instructions to evacuate the area. This mitigates risks from battery fires when parked indoors. The system also disconnects the battery to prevent spreading.

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A monitoring and protection system for energy storage devices like batteries that provides real-time monitoring and protective actions to mitigate failures and enhance safety. The system has temperature and deformation sensors on each battery module. A control unit receives the data and triggers protective actions based on the readings. This allows proactive response to abnormal conditions like overheating or deformation, preventing cascading failures and catastrophic events like fires.

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Accurately estimating the temperature of a hotter area inside a battery module using a temperature sensor located in a cooler area. The technique involves adding a correction term to the sensor reading that scales with the rate of change of the sensor value. This prevents the estimated temperature from overshooting when the sensor is affected by noise. The correction term is set such that the estimated temperature rise rate in the hotter area doesn't exceed a predetermined value.

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Real-time temperature measurement for traction battery packs using deep learning to improve accuracy compared to traditional methods. The technique involves using a generative adversarial network (GAN) with a three-dimensional convolutional neural network to infer the battery pack's full temperature field from limited measured points. It leverages the GAN's generative capability to generate a 3D temperature field that matches the measured data. This preserves the spatial correlation of the pack temperature distribution.

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Battery module design to accurately measure internal temperature for improved performance at high discharge rates. The design involves compressing a thermistor against the top cover of the battery using a component on the external wiring harness board. This forces the thermistor to contact the cover and accurately detect its temperature. The cover temperature closely matches the internal battery temperature. By measuring the cover instead of the external sheet, it provides a more accurate representation of the battery's internal temperature as the cover closely follows the battery temperature changes.

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Battery design with through-stack fasteners and channels for improved monitoring, cooling, and swelling compensation. The battery has multiple circuit boards with aligned apertures through the active cell regions. Fasteners extend through these channels to connect the circuit boards. Conductive extensions on the cells connect to the fasteners. This allows monitoring, cooling, and swelling compensation through the fasteners instead of internal probes. The fasteners also provide electrical connections between cells and thermal paths for cooling. The channels allow heat transfer and swelling compensation across the cell stack.

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Temperature sampling assembly for batteries to improve reliability and accuracy of temperature monitoring. The assembly has a modular design with a sampling circuit board that can be detached from the battery component being measured. This prevents adhesive failure and sensor detachment due to high temperatures. The circuit board has a sampling part with a temperature sensor chip, connected to a heat spreading base via adhesive. The base conducts component heat to the chip. The base can then attach to the battery component. Flexible adhesive on the board allows expansion/contraction mismatch without breaking. This assembly allows independent modular temperature sensing that can be moved between components without adhesive loss.

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Abstract Large prismatic cells are increasingly being used as the primary power source in transportation applications. Effective online thermal management of these is crucial for ensuring safety and maximizing performance. However, significant discrepancies between surface internal temperatures make it difficult to detect anomalies promptly, which hinders effective increases risk irreversible hazards. This paper introduces an innovative technology Liion batteries. By exploiting temperature sensitivity ultrasound velocity applying tomographic reconstruction based on surrounding measurements, enables detailed crosssectional imaging. allows nondestructive, realtime visualization temperatures. Furthermore, with its compact design costeffectiveness, this suitable insitu deployment, offering a precise feedback mechanism management. Demonstrations conducted during continuous discharging scenarios have shown that system can identify hightemperature regions near tabs remain undetected by thermocouples. advancement has potential significantly reduce fires or explosions whi... Read More

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Efficient thermal management of lithium-ion batteries is crucial for electric vehicle safety and performance. This study investigates immersion cooling in serpentine channels 18650 batteries, aiming to identify key factors affecting maximum battery temperature (Tmax) pump power (Pw). A Box-Behnken experimental design implemented with Computational Fluid Dynamics simulations analyze responses Tmax Pw. Five variables are defined: partition length (Lp), charging/discharging rate (Crate), coolant volumetric flow (V), inlet (Tin) ambient (Tamb). Statistical significance evaluated via Analysis Variance. The results show that: Tin dominated Tmax, followed by Crate, V, Lp. Significant interactions (VTin VTamb) observed. For Pw, V V extreme significance, while Lp effects were minor. Interaction LpV was significant but secondary. After optimization minimize Tave the optimal values Lp, Tin, Tamb determined be 89.5 mm, 1.08 C, 0.51 LPM, 20 C, 25.62C respectively. corresponding optimized are: = 22.87C, 21.67C, Pw 0.279 mW. Optimal requires prioritizing control suppression regulati... Read More

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In this investigation, a comprehensive validation framework for an integrated electrochemical-thermal model that addresses critical thermal management challenges in lithium-ion batteries (LIBs) is presented. The two-dimensional numerical combines the NewmanTiedemannGuKim (NTGK) battery with enthalpy-porosity approach phase change material (PCM) systems (BTMSs). Rigorous against benchmarks demonstrates models exceptional predictive capability across wide range of operating conditions. Simulated temperature distribution and voltage capacity profiles at multiple discharge rates show excellent agreement experimental data, accurately capturing underlying mechanisms. Incorporating Capric acid (with transition 302305 K) as PCM, significantly improved accuracy over existing models literature. Notable error reductions include 78.3% decrease Mean Squared Error (0.477 vs. 2.202), 53.4% reduction Root (0.619 1.483), 55.5% drop Absolute Percentage Error. Statistical analysis further confirms robustness, high coefficient determination (R2 = 0.968858) well-distributed residuals. Liqu... Read More

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Battery cell design with integrated distributed temperature sensing using optical fibers. Multiple grating temperature measurement points are formed on an optical fiber that is arranged on the battery cell body. This allows precise and distributed temperature monitoring of the cell without requiring external thermistors. The grating structure on the optical fiber reflects specific wavelengths when temperature changes, providing distributed temperature sensing points along the fiber.

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This study presents an experimental investigation of a novel hybrid battery thermal management system (BTMS) that integrates solenoid-actuated Peltier-based heat sink with CuO/ethylene glycol (EG) nanofluid coolant loop. The delivers on-demand cooling through time-controlled thermoelectric operation, enhancing temperature regulation during surges. Experiments were conducted CuO nanoparticle concentrations ranging from 0.5% to 2.0% (vol.) and flow rates 1 5 LPM, at inlet 50C ambient 26C. Performance metrics such as drop, transfer rate, overall coefficient analyzed. Results showed maximum enhancement 40.63% (tube-side) 38.64% (air-side) CuO. Compared conventional liquid system, the setup demonstrated 7.01% higher rate improved variation control (up 28.53%). Life Cycle Cost (LCC) analysis demonstrates 25%30% reduction in long-term costs 36% life extension, supporting systems economic viability. scalable, energy-efficient BTMS offers promising solution for advanced electric vehicles requiring high-precision control.

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Monitoring battery systems like electric vehicle batteries to detect and prevent thermal runaway events during inactive periods when the battery management system is powered down. The method involves using sensors to continuously monitor cell voltages and temperatures when the system is not in use. If a predefined wake-up time passes, a new wake-up time and default values are calculated based on measured value gradients and limits. This allows waking the system earlier to prevent runaway if gradients indicate approaching limits. If measured values exceed limits, it's an emergency and the system wakes immediately. This improves safety by catching runaways sooner during inactive periods.

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A good thermal management system for batteries is the key to solving potential risks such as runaway of and ensuring that work within appropriate temperature range. To resolve conflict between cooling efficiency input power in existing battery systems based on thermoelectric cooling, this paper proposes an optimization method layout devices. Using a multi-physics coupling numerical model, study focuses analyzing impact quantity devices current temperature. The optimal arrangement structure response characteristics are investigated from four aspects: maximum temperature, difference, difference uniformity, coefficient. research results show optimized capable reducing both pack, reduces consumption by 19.8%, effectively enhancing energy system.

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The study presents a thorough theoretical analysis of the thermal distribution in electric vehicle battery packs under different heating loads. A finite-element heat transfer model is developed COMSOL to simulate pack with 15 cylindrical lithium-ion cells integrated liquid-cooled support plates. C-rates, which define generation during charge-discharge cycle, are included model-in real case scenarios wherein 10 Ah generates outputs about 10.5 W, 25 and 54 W at 3C, 5C, 8C charge rates, respectively. Transient simulations display how temperature profiles evolve time reach quasi-steady states by input counterbalanced dissipation through convection. It also examines air convection performance as technique for cooling, revealing that while it cheaper simpler implement, less effective than liquid cooling. Other alternatives this regard, such use graphite foam, have been investigated concerning their ability achieve higher coefficients, thus enhancing load management greater rates charge. results illuminate importance optimized systems avert runaway EV ensure safety, efficiency, longevity. w... Read More

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Battery prognostics tool that can predict and alert for thermal runaway events in batteries even when the battery management system (BMS) is turned off or failed. The tool uses cell temperature sensors to monitor cells when the BMS is not operational. It compares the cell temps to a thermal model to predict runaway risk. If a runaway is predicted, an alarm is output to alert of the potential issue. This allows early warning of runaway even when the BMS is not functional.

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Early fire risk detection in vehicles using optical fiber temperature sensors placed near critical components like batteries, fuel cells, pumps, etc. The sensors have a tunable light source, interferometer, detector, and signal processing module. The sensors use a short periodic light source waveform and wavelength tuning to achieve high spatial resolution temperature monitoring. The sensors detect temperatures exceeding thresholds and generate alarms. This allows early warning of overheating components before fires start.

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Vacuum pressure sensor with a contamination shield to prevent sensor degradation due to process contamination. The sensor has a diaphragm and electrode forming a capacitive structure in a sealed cavity. A support structure holds the diaphragm. A contamination shield between the inlet and diaphragm provides fluid paths crossing the diaphragm plane multiple times. This allows media to reach the diaphragm without direct exposure through the inlet, preventing contamination accumulation. The shield can have apertures, walls, and labyrinths to guide the paths.

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In the context of global energy transition, thermal management electric vehicle batteries faces severe challenges due to temperature rise and consumption under dynamic operating conditions. Traditional strategies rely on real-time feedback suffer from response lag efficiency imbalance. this study, we propose a neural network-based synergistic optimization method for driving conditions prediction management, which collects multi-scenario real-vehicle data (358 60-s condition segments) by naturalistic collection method, extracts four typical (congestion, highway, urban, suburbia) combining with K-means clustering, constructs BP (backpropagation network) model (20 neurons in input layer 60 output layer) predict speed next s. Based results, coupled PID control mechanism dynamically adjusts coolant flow rate (maximum reduction 17.6%), reduces maximum battery 3.8 C, difference 0.3 standard deviation fluctuation at ambient temperatures 25~40 C is 0.2 AMESim simulation experimental validation. The results show that strategy significantly improves safety system economy complex working pro... Read More

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Abstract Lithiumion batteries play a crucial role in reducing carbon emissions and promoting the use of electric vehicles. There are numerous input variables influencing thermal profile lithiumion batteries. Therefore, precise assessment relative contributions various factors is essential for optimizing management control processes. In this study, we tested battery pack composed five 14.6 Ah prismatic cells connected series under different discharge rates (2C, 3C, 4C, 5C), ambient temperatures (30, 35, 40, 45C), convective heat transfer coefficients (5, 10, 20, 40 ). Results showed that temperature with contribution 58.01% had strong influence on maximum temperature. Furthermore, influences Crate coefficient were identical. Moreover, it was found homogeneousness very sensitive to Crate, contributing 71.07% increase difference. To ensure uniformity at same time, moderate temperatures, low Crates, high can be preferred. Consequently, statistically obtained results study may contribute towards performance optimization improved safety packs.

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Smart vehicle systems for detecting and responding to severe thermal events in rechargeable battery packs. The systems employ wireless communication protocols to monitor battery temperature and surrounding environment, and automatically detect nearby vehicles or pedestrians within a defined proximity. They then assess the severity of the thermal event using data from both the battery and surrounding environment, and trigger appropriate vehicle responses such as alerts, system shutdown, or control actions to mitigate the thermal event.

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Abstract Lithium-based batteries (LiBs) are integral components in operating electric vehicles to renewable energy systems and portable electronic devices, thanks their unparalleled density, minimal self-discharge rates, favorable cycle life. However, the inherent safety risks performance degradation of LiB over time impose continuous monitoring facilitated by sophisticated battery management (BMS). This review comprehensively analyzes current state sensor technologies for smart LiBs, focusing on advancements, opportunities, potential challenges. Sensors classified into two primary groups based application: optimization. Safety sensors, including temperature, pressure, strain, gas, acoustic, magnetic focus detecting conditions that could lead hazardous situations. Performance optimization such as optical-based electrochemical-based, monitor factors charge health, emphasizing operational efficiency lifespan. The also highlights importance integrating these sensors with advanced algorithms control approaches optimize charging discharge cycles. Potential advancements driven nanotechnolo... Read More

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Temperature measurement apparatus for battery modules that improves assembly efficiency and accuracy of temperature sensing. The apparatus has a holder with an alignment hole, a substrate with a temperature sensor, and protection members on both sides. A support member aligns the substrate with the hole. This prevents random movement of the sensor during assembly. Insulating members between the battery and terminals further prevent sensor misalignment. This reduces errors by fixing the sensor position and simplifying assembly compared to double-sided soldering.

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Battery cell design and pack protection to prevent thermal runaway in lithium-ion batteries. The battery cell has temperature labels at different positions. If the temperature difference between them exceeds a threshold, it indicates an abnormal state. When detected, the cell's charging/discharging switch is turned off to prevent further use, and a fire extinguisher inside the cell activates to prevent thermal propagation.

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Method for detecting electrical fault states in removable battery packs using integrated temperature sensors. The method involves measuring the temperature of the battery pack using a first monitoring unit with integrated sensors, and measuring the temperature of individual cells using temperature sensors within the battery pack. The pack's monitoring unit evaluates both temperatures and adapts charging/discharging currents based on the combined data. If the cell and pack temperatures differ by more than a threshold, it indicates local temperature differences. This enables more accurate compliance with cell specifications and prevents faults. The method involves connecting the battery pack and device with contacts for power, signals, and temperature monitoring.

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Abstract This paper proposes a versatile thermal management solution utilizing phase change material (PCM) for compact 21700 battery modules. First, flame-retardant and heat-conductive pouring sealant is utilized to encapsulate the PCM. The impact of diameter number PCM columns on performance module evaluated by single-factor multi-objective optimization methods. Then, low-temperature heating scheme film heaters devised module. results indicate that heat generation diminishes as working temperature rises, whereas it escalates with an increase in discharge rate. When 8 inner outer heights are 66 mm 13 mm, maximum difference controlled at 45.6 C 4.61 C, respectively. With power 13.6 W, average may from -5 11.7 25 minutes, resulting differential 4.6 C.

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The increasing adoption of electric vehicles (EVs) necessitates advancements in battery management systems (BMS) to enhance safety, performance, and longevity. This comprehensive review explores advanced tools technologies integral modern BMS, emphasising their roles optimising EV efficiency safety. Key areas discussed include the application machine learning algorithms for predictive maintenance, sensor integration accurate system monitoring, thermal solutions mitigate overheating risks. Additionally, highlights innovative use digital twins real-time diagnostics cloud computing expansive data analysis. These collectively improve reliability functionality crucial broader acceptance success market.

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Battery cell assembly with accurate temperature measurement for improved safety and a manufacturing method for it. The assembly uses a thermistor to measure the temperature of the battery cell. The thermistor is mounted on the PCB outside the cell, and a thermally conductive adhesive is added between the thermistor and cell to transfer heat. This allows accurate temperature measurement compared to when the thermistor is isolated. The adhesive bridge enables direct thermal connection between the cell and thermistor.

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Integrated thermal switching and sensing devices for electrical connectors that provide overtemperature protection and monitoring for electrical components like batteries. The devices are integrated inside the connector body and thermally coupled to the component terminals. They have a thermal switching element and a thermal sensor in parallel. When the component temperature exceeds a threshold, the switching element opens and the sensor resistance increases. This signals an overtemperature to an external control device. The switching element prevents further current flow while the sensor provides a temperature alert.

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Method for producing a traction battery for electric vehicles that enables rapid and inexpensive production of the battery while enabling accurate temperature measurement. Each battery cell in the module has a separate temperature sensor. The sensor is mounted on a metal carrier that is welded to the cell housing. This allows direct thermal contact between the sensor and the cell housing for accurate temperature measurement. The connector that electrically connects the cells is also welded in the same step.

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Electric vehicles (EVs) are pivotal in reducing greenhouse gas emissions and achieving sustainable transportation goals. However, lithium-ion batteries (LIBs), the primary energy source for EVs, face critical thermal management, safety, long-term efficiency challenges. This study proposes an integrated battery management system that combines a waterethylene glycol-based liquid cooling mechanism with high-conductivity copper tubing to enhance LIB performance, longevity, safety. Through COMSOL multiphysics simulations, this examines behavior under varying operational conditions. The results indicate 20% reduction temperature peaks, maintaining optimal range of 15C 35C, thus mitigating risks runaway. Experimental validation using infrared thermography imaging confirms system's efficiency, showing maximum recorded 43.48C load conditions, significantly lower than unmanaged systems. Beyond work integrates advanced strategies, including state-of-charge estimation, predictive fault diagnostics, active optimization, cell balancing. analysis further reveals proposed improves heat diss... Read More

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Battery thermal management systems (BTMS) ensure the safety and performance of lithium-ion batteries, which power electric vehicles. However, designing an effective BTMS is challenging due to batteries' complex behaviour sensitivity temperature variations. This review comprehensively explores current vital technologies trends in BTMS, explicitly focusing on analysing various cooling control strategies. To discuss four primary technologies: air cooling, liquid immersion phase change material (PCM) cooling. The advantages disadvantages each technology are compared terms cost-effectiveness, applicability, limitations when dealing with high-energy-density batteries. Furthermore, delves into discussion strategies data prediction methods for emphasizing importance advanced analysis optimising battery safety. Different strategies, such as passive, active, hybrid control, introduced evaluated. Data methods, artificial neural networks, fuzzy logic, machine learning, also presented discussed. comprehensive provides in-depth understanding while serving a valuable reference future research appli... Read More

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Temperature sensor for battery modules in electric vehicles that has a housing made of a specific polymer composition that allows high flow properties and good heat resistance. The polymer composition contains a thermotropic liquid crystalline polymer and has a melt viscosity of 300 Pa-s or less and a deflection temperature under load of 170° C or more. This allows the sensor to have high flowability during molding and processing while also having good short-term heat resistance during operation. The combination of low melt viscosity and high DTUL provides a balance between processability and heat resistance for the temperature sensor housing material.

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System and control methodology for heating and charging battery packs using AC power, enabling rapid and efficient thermal management. The system integrates AC power delivery with a temperature-controlled heating circuit, where the heating element is controlled by a temperature sensor. The charging circuit includes rectifier switches, a transformer, and a series switch. During charging, the charging circuit injects AC current into the battery through the series switch, while the heating circuit injects DC current through a transformer and series switch. This synchronized operation ensures uniform heat distribution across the battery pack.

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Thermal regulation system for vehicle batteries that provides safe and reliable operation of high-power batteries in vehicles. The system uses a closed fluid network with a pump to circulate dielectric heat transfer fluid through the battery modules. Temperature sensors monitor the battery and the fluid. A control unit switches between free circulation, heating, and cooling modes based on sensor readings. This allows precise temperature control of the batteries without relying solely on ambient cooling or active cooling devices.

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System for controlling battery temperature and power consumption in electric vehicles to avoid battery voltage drop without sacrificing driving range. The system has a temperature sensor, heater, battery controller, and drive controller. When the battery temperature is low but charge is high, the drive controller instructs the battery controller to heat the battery. When the battery temp is low and charge is low, the drive controller limits power consumption. This prevents voltage drop due to increased internal resistance when heating is stopped. By balancing heating and power limits, the system extends battery life without sacrificing range.

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A portable device for testing multiple temperature sensors simultaneously in the field without requiring user intervention to select which sensor to test. The device automatically tests each connected sensor in sequence and provides results for leakage current, functionality, and temperature accuracy. It can detect short circuits, broken sensors, and disconnections. This improves efficiency compared to manually testing one sensor at a time.

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ABSTRACT A ratiometric timedomain temperature sensor is presented in this work. The frontend of the generates two temperaturedependent currents: proportional to absolute (PTAT) and complementary (CTAT), which bias ring oscillators, first PTAT clock second CTAT clock. clocks are combined within an alldigital sigmadelta converter consisting up/down counter, a FlipFlop, 12bit counter. occupies area only 0.019 mm 2 , gives it advantage over vast majority smart sensors 180nm technology, including some lower nodes. min/max accuracies measured 12 parts 0.6/+6.6C achieved with 1point 2.7/+2.3C 2point trimming. nominal resolution 0.3C (effective 0.37C ENOB 8.8 bits) measuring range 40 125C.

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Electric vehicle (xEV) battery durability significantly impacts the long-term operation, consumer satisfaction, and market adoption of xEVs. As driving range diminishes over time, it affects service life lifecycle GHG emissions. Measuring full xEV batteries in laboratory tests presents technical logistical challenges, necessitating representative measurements for parameterizing numerical models. These models are crucial predicting performance rely on high-quality experimental data. While aging trends under extreme temperatures documented, cell thermal contact conditions suitable direct model input not well characterized. This study investigates lithium-ion cells from three types, cycled at constant currents C/40 to 1C, between 15 C +45 C, 1000 cycles a multi-year campaign. Stable isothermal were achieved using custom-built liquid immersion baths with forced convection, highlighting fundamental electrochemical behaviors by decoupling complex self-heating typically monitored air environments. The data inform validate physics-based temperature-dependent durability, providing oper... Read More

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Electrical module and battery pack design for improving voltage and temperature collection accuracy in electric vehicles. The design brings the cell voltage and temperature sensors closer to the module's electrical interface to reduce signal transmission length. This is done by integrating the sensor circuitry into the module instead of using separate sensors and cables. The module has a cells contact system to collect voltages and temperatures, and an on-board cell supervision circuit with analog front ends to convert the signals. This reduces the length of analog signal transmission compared to conventional designs with separate sensors and cables. The closer proximity of the sensors to the module interface reduces transmission path interference and improves voltage and temperature accuracy.

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Diagnosing battery pack health through precise voltage and temperature monitoring. The system measures and analyzes the voltage and temperature of individual battery cells, then applies predictive balancing to restore their normal operating ranges. The monitoring process continues until the battery pack's voltage reaches a predetermined cutoff point, enabling the system to diagnose cell health based on the remaining voltage, temperature, and average values.

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Thermal management system for energy storage battery packs that improves cooling efficiency and extends battery life by individually controlling fan speeds based on module temperatures. Each battery pack has a temperature sensor, fan, and controller. The controllers adjust fan duty cycles based on module temperature compared to a threshold. This allows fan speeds to vary pack-to-pack since temperatures can differ. By tailoring cooling to each pack's heat needs, it prevents hotspots and improves pack consistency.

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A flexible battery pack design and thermal management system for electric vehicles that enables better cooling of the battery pack and prevents hot spots. The pack has a J-shaped layout with four sections, an intake port, and two exhaust ports. Two control valves can independently adjust the flow of cooling fluid from each exhaust port. Sensors measure temperatures in the two sets of batteries. This allows real-time, adaptive cooling based on the temperature difference between sections. The J-shaped layout and separate exhaust valves provide flexibility to optimize cooling for variable conditions.

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Battery module with integrated temperature sensing and overcharge protection that uses only one input port of the protection IC chip to detect high cell temperatures. A series of positive temperature coefficient (PTC) thermistors surround each cell and connect to the IC input. When any cell temperature exceeds a threshold, the voltage drop across the PTCs changes and triggers overcharge blocking through the IC.

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Battery pack with integrated temperature and swelling monitoring to improve safety and performance. The pack has a composite panel that attaches to the cell surface. The panel has separate sections for heat dissipation, heating, and sensing. The heating section contains a circuit to generate heat. The sensing section has electronics to measure cell temperature and swelling. This allows active temperature control and swelling detection without needing additional components in the pack.

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Intelligent temperature monitoring and alarm system for electric vehicle batteries to mitigate thermal runaway risks. The system enters a low power sleep mode and wakes periodically to check battery temperature. If below a threshold, it returns to sleep. If above, it enters a first alarm state. This allows longer battery life by reducing unnecessary power draw during temperature checks. The threshold is set above safety limits but below fire threshold. If temperature exceeds a second threshold, a second alarm is triggered. The intervals are dynamically adjusted based on other vehicle data.

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A monitoring system for battery storage systems that provides accurate and consistent monitoring of individual battery packs to enable reliable warranty and insurance claims. The system involves selectively monitoring a subset of battery packs in a storage system using dedicated monitoring devices rather than relying on lower quality vendor supplied monitoring systems. Each device has sensors to measure pack voltage, temperature, current, and cell voltage/temperature. The data is stored in the device's memory for verification. This provides more accurate and consistent monitoring compared to vendor systems with lower quality components.

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Electric vehicle charging plug with improved sealing to prevent moisture ingress while allowing accurate internal temperature monitoring and remote cutoff control. The plug has temperature sensors inside to detect overheating. It has multiple seals around the pins and faceplate to prevent water entry. An outer mold covers everything. The seals around the pins have ledges inside the slots. The outer mold seals cover the seals and lower faceplate parts. This prevents moisture from reaching the sensors. A separate controller cuts power if the plug overheats based on the remote temperature data.

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Determining temperature in a sensor using the pulse width of its output signals. The sensor transmits pulses according to a protocol. By measuring the pulse width and comparing it to reference data, the temperature in the sensor can be inferred. The reference data is obtained by repeatedly transmitting sensor data during production when the sensor is being heated and cooled. The pulse width-temperature relationship is gauged during these steps.

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Abstract This paper proposes a gravity heat pipe-air hybrid temperature control system to address the inadequate dissipation in power batteries under high-rate discharge conditions when using single cooling methods. The systems performance was evaluated for series-arranged battery packs at rates above 5C. Results show that effectively meets thermal management requirements 3-cell 5C, but as number of cells increases seven, degrades, with uniformity exceeding 5 C threshold, leading failure. To resolve this, C-shaped configuration adopted improved pack arrangement. Further analysis demonstrates optimized manages up 7C within air span 20 35 C.

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