Temperature Sensors for EV Battery Monitoring

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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Accurately measuring battery temperature using an integrated circuit (IC) already present in the battery pack, instead of adding separate temperature sensors. The IC contains a voltage sensor, temperature sensor, and processing logic. To calibrate, the thermal resistance between the IC and battery terminal is estimated by measuring temperatures with different current draw. During normal operation, the IC measures voltage, current, and temperature. It calculates power consumption and self-heating from the voltage and current. The self-heating is then subtracted from the measured temperature to compensate for the IC's own heat generation.

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Assembly for thermal management of individual cells in a battery pack that allows precise temperature control of each cell. The assembly has multiple features to address temperature regulation needs: 1. Thermal insulation between cells to prevent heat transfer. 2. Fluid passages for cooling or heating the cells. 3. Valves and flow control to selectively circulate fluids. 4. Temperature sensors and actuators to respond to cell conditions. 5. Fluid supplies for different operating conditions. The assembly enables independent temperature regulation of each cell without mixing fluids between cells. This prevents overheating or cooling of cells while avoiding thermal runaway. The fluid flow control allows customization based on factors like discharge level, charging rate, and ambient temperature.

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Vehicle with battery compartment safety system that automatically opens the compartment covers when battery temperature reaches a critical level to prevent thermal runaway propagation. The system uses thermosensitive devices to detect high battery temperature and pneumatic actuators to instantly open the compartment covers. This allows rapid cooling to contain thermal runaway without needing manual intervention.

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Battery temperature measurement system and control method for electric vehicles to improve battery safety and accuracy. The system has multiple temperature sensors in each battery cell group, core group, and ambient area. This provides full temperature detection inside the battery. The BMS uses the sensor data to control battery cooling and charging based on cell, core, and ambient temps. This allows balancing temperatures and preventing excessive differences.

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Battery cell design for accurate temperature measurement in high-voltage batteries for electric vehicles. The battery cell has a separate thermally conductive part inside the housing that connects to the temperature sensor. This allows more accurate measurement of the cell interior temperature compared to an external sensor since it eliminates insulation barriers. The conductive part is separate from the electrode to avoid current interference.

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Battery module with a temperature sensor that accurately measures the internal battery temperature to prevent premature power limiting in high load conditions. The sensor is installed in the battery housing rather than on the external connection strap. This allows it to better reflect the internal battery temperature. The sensor is located inside a plugging member that fits into the battery cover. The cover has a temperature collection hole and sink groove for the sensor. This arrangement enables timely and accurate internal battery temperature monitoring to prevent power limiting due to temperature differences between the external connection and internal battery.

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Real-time temperature detection method for battery packs using deep learning and convolutional neural networks to accurately predict battery pack temperatures based on measurements at limited sampling points. The method involves training a 3D convolutional neural network to take input of battery voltage, current, and temperature at a few points and output the entire 3D temperature field of the pack. This leverages the correlation of spatial data in the pack and allows more realistic prediction compared to 2D models.

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A battery cell temperature measurement system for electric vehicles that allows non-invasive, contactless temperature monitoring of individual battery cells in a pack without requiring physical access to the cells. The system uses optical sensors placed on the module frame to measure temperature through apertures in the frame. A Cell Monitoring Unit (CMU) generates cell temperatures based on the optical measurements. This provides a quick, non-contact way to monitor cell temperatures without touching the cells or modifying the pack design.

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Battery control system to prevent degradation of battery cells due to temperature imbalance between cells. The system has temperature sensors on cells at different locations in the battery pack. It monitors the temperatures of cells at opposite points. If temperature difference exceeds a threshold, the controller performs compensation actions to balance the cells. This can involve adjusting charge/discharge rates or cell balancing algorithms to account for the temperature mismatch. This prevents imbalance-induced degradation when cells operate at different temperatures.

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Battery cell design with improved temperature sensing for more accurate temperature monitoring and capacity utilization. The battery cell has a temperature sensor array on the cell body instead of just one point. This allows measuring temperatures at multiple locations inside and outside the cell, reducing errors compared to single point measurement. The sensor area is at least 10% of the cell surface. The sensor is a stacked film with insulating layers and a sensing layer. By increasing sensor contact with the cell body, it provides more accurate temperature data for battery management.

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Battery pack temperature sensing device that provides improved safety and real-time monitoring of battery pack temperatures compared to traditional methods. The device uses a thermal conductive core with an exposed surface connected directly to the battery cells. This core collects temperature from all the cells and transfers it to a temperature sensing element. The sensing element converts the temperature signal into an electrical signal. This allows continuous monitoring of all cell temperatures, rather than just a few points. The sensing element can detect abnormal temperatures earlier, giving time for action, as heat accumulates in the core before reaching the sensing surface. The device also uses an insulating layer to cover part of the core surface, exposing the sensing surface to the cells.

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Battery module with temperature sensors to accurately monitor battery temperature in different areas. The module has two temperature sensors, one closer to the battery pole and the other farther away. This allows collecting temperature values from high and low regions of the battery. The sensor positions enable comprehensive and accurate battery temperature monitoring compared to using a single sensor. This helps optimize battery performance and longevity by ensuring it operates at suitable temperatures.

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A fault diagnosis method for battery management systems that can detect faults in sensors like temperature sensors inside the system. The method uses uncertain noisy filtering to estimate sensor faults by extending the state constraint of the battery system to the system output vector. This allows detecting faults in sensors with constraints like temperature limits. The method involves constructing an augmented system with expanded fault vectors and state constraints, then using a zonotope Kalman filter to estimate fault intervals. If the estimated fault bounds exceed the normal range, it indicates a sensor fault.

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Detecting thermal events in battery packs of electrified vehicles while accounting for faulty sensors. The method involves flagging temperature readings from sensors as reliable or unreliable based on assessments. If a sensor is flagged reliable, its temperature reading is used to detect thermal events. But if a sensor is flagged unreliable, its temperature reading is ignored. This prevents using inaccurate readings from faulty sensors to falsely trigger thermal event alerts.

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Battery thermal management method that provides faster response to thermal events compared to traditional monitoring methods. The technique involves calculating temperature gradient changes between sensors in a heat correlation network. By analyzing how temperature is spreading between sensors, it can more quickly identify localized hot spots and potential thermal runaway issues compared to just monitoring individual sensor readings. The gradient changes are used to trigger alarms for abnormal temperature propagation.

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Battery monitoring method that allows detecting and predicting battery conditions even during sleep mode. The method involves periodically waking up the battery during idle periods to measure temperature, storing the individual measurements, and determining a continuous temperature exposure at rest. This is combined with temperature during operation to get a complete battery temperature exposure. This allows monitoring the battery even when powered off. The battery has temperature sensors on cells and a central temperature sensor. The battery management system, central control unit, and consumer can all participate in temperature monitoring and storage.

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