Temperature Sensors for EV Battery Monitoring

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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A liquid cooling module for vehicles that simplifies the deployment of a temperature sensor to monitor cooling fluid temperature inside the module. The module has a cold plate with a protrusion on one side. The circuit board is attached to the main body of the cold plate using the protrusion as a fastener. The temperature sensor is located on the circuit board adjacent to the protrusion. The sensor is connected to the protrusion using a thermally conductive medium to measure the cooling fluid temperature. This eliminates the need for a separate installation process for the temperature sensor.

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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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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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Vehicle safety monitoring system that detects tire pressure, engine temperature, and battery health in real-time to prevent accidents. The system integrates tire pressure monitoring, engine temperature monitoring, and battery health monitoring through a networked architecture. It uses advanced sensors to detect tire pressure drops, engine temperature anomalies, and battery cell health indicators. The system automatically alerts the driver through audible and visual warnings, with automatic intervention when critical conditions are detected. The system also integrates with vehicle management systems to enable remote monitoring and emergency response capabilities.

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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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Temperature collecting device for batteries that simplifies assembly and improves temperature measurement accuracy. The device has a base plate with an integrated NTC sensor and encapsulation. The base plate connects to FPC and busbars instead of complex sensor fixtures. This allows direct contact with cell surfaces for temperature measurement. It eliminates the need for separate sensor fixing structures. The base plate design provides better heat dissipation, faster assembly, and easier temperature data transfer compared to traditional sensor mounting.

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A battery cell temperature sensing system for electric vehicle batteries that provides improved temperature measurement accuracy and reliability. The system uses a custom sensor design with a compact sensor body that is sandwiched between the battery cell and the battery housing base. The sensor body has separate supports for attaching to the cell and housing base. The sensor element is enclosed in a recess in the housing base support. This configuration allows the sensor to be tightly sandwiched between the cell and housing for accurate temperature measurement, while also protecting the sensor from the battery cooling medium.

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Controlling battery thermal management in electric vehicles to prevent thermal runaway from spreading between battery modules. The method involves detecting battery cell temperature and voltage to identify the location of thermal runaway. Then, heating devices near the thermal barrier on the opposite side of the runaway cell are activated to generate heat. This minimizes thermal transfer to the barrier and prevents further spread. The technique allows reducing barrier thickness without risking runaway propagation.

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Integrated temperature probe for monitoring battery cell temperatures inside a stack of battery cells in an electric vehicle. The probe is placed between the electrode layers of a cell without altering cell operation. It consists of two materials partially coating the separator that overlap at an overlap region. Sensor terminals are connected to the materials. A voltage differential between the terminals corresponds to the average temperature at the overlap region. Multiple probes in different cells provide cell stack temperature mapping.

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