Multiple-zone thermocouple battery module temperature monitoring system
A multiple-zone thermocouple battery module temperature monitoring system is provided configured to determine a plurality of temperatures along a depth of the battery module at different locations. The system may include a number of temperature probes each including a first temperature sensor oriented at a base of a group of cells in the module and a second temperature sensor oriented at an upper portion of the group of cells in the module. Providing upper and lower battery cell temperature sensors in each probe of the system allows a battery management system to detect and record a temperature gradient of the battery cells in the module at a number of different locations. These recordings can determine a gradient and temperature difference between the upper and lower battery cell portions over an operable threshold difference, and command a thermal management system to return the battery module to limits within the operable threshold.
1. A multiple-zone battery module temperature monitoring system, comprising:
a first temperature probe comprising a first probe end spaced apart from a second probe end, wherein the first temperature probe is disposed at a first location of a battery module in an area between three or more immediately adjacent battery cells, wherein the first probe end is arranged adjacent to first ends of the three or more immediately adjacent battery cells, wherein the second probe end is arranged adjacent to second ends of the three or more immediately adjacent battery cells, and wherein the first temperature probe comprises:
a first temperature sensor that is disposed adjacent to the first probe end and that measures a temperature of a first stratum of the first ends of the three or more immediately adjacent battery cells; and
a second temperature sensor that is disposed adjacent to the second probe end and that measures a temperature of a second stratum of the second ends of the three or more immediately adjacent battery cells independently of the first temperature sensor; and
a processor that receives measurement data of the temperature of the first stratum from the first temperature sensor and different measurement data of the temperature of the second stratum from the second temperature sensor of the first temperature probe.
2. The multiple-zone battery module temperature monitoring system of claim 1 , further comprising:
a second temperature probe disposed at a second location of the battery module spaced apart from the first location in an area between three or more different immediately adjacent battery cells, wherein the second temperature probe comprises:
a first temperature sensor disposed adjacent to a first probe end of the second temperature probe; and
a second temperature sensor spaced apart from the first temperature sensor and disposed adjacent to a second probe end of the second temperature probe.
3. The multiple-zone battery module temperature monitoring system of claim 2 , wherein the processor receives data from the first temperature sensor and the second temperature sensor of the second temperature probe, wherein the data from the first temperature sensor of the second temperature probe corresponds to a temperature measurement in a first stratum associated with first ends of the three or more different immediately adjacent battery cells, and wherein the data from the second temperature sensor of the second temperature probe corresponds to a temperature measurement in a second stratum associated with opposite second ends of the three or more different immediately adjacent battery cells.
4. The multiple-zone battery module temperature monitoring system of claim 3 , wherein the processor determines a difference between the temperature measurements in the first and second strata of the first temperature probe and determines a difference between the temperature measurements in the first and second strata of the second temperature probe.
5. The multiple-zone battery module temperature monitoring system of claim 4 , wherein the first temperature probe includes an elongated housing extending a length from the first probe end to the second probe end of the first temperature probe, and wherein the second temperature probe includes an elongated housing extending the length from the first probe end to the second probe end of the second temperature probe.
6. The multiple-zone battery module temperature monitoring system of claim 5 , wherein the first and second temperature sensors of the first and second temperature probes are disposed at least partially within the elongated housing of the first and second temperature probes, respectively.
7. The multiple-zone battery module temperature monitoring system of claim 6 , wherein the first and second temperature probes are electrically interconnected via a flexible printed circuit substrate running from the second probe ends of the first and second temperature probes to the processor.
8. A battery module, comprising:
an array of battery cells arranged in adjacent spaced apart series-connected rows, the adjacent spaced apart series-connected rows being spaced apart along a length of the battery module running from a first end to an opposite second end of the battery module, wherein all positive terminals for each battery cell in the array of battery cells are oriented facing a same direction; and
a multiple-zone battery module temperature monitoring system, comprising:
a first temperature probe disposed at a first location of the battery module in an area between three or more immediately adjacent battery cells in the array of battery cells, the first temperature probe comprising a first probe end spaced apart from a second probe end, wherein the first probe end is arranged adjacent to first ends of the three or more immediately adjacent battery cells, wherein the second probe end is arranged adjacent to second ends of the three or more immediately adjacent battery cells, wherein the first probe end comprises a first temperature sensor that measures a temperature of a first stratum of the first ends of the three or more immediately adjacent battery cells, and wherein the second probe end comprises a second temperature sensor that measures a temperature of a second stratum of the second ends of the three or more immediately adjacent battery cells independently of the first temperature sensor; and
a processor that receives measurement data of the temperature of the first stratum from the first temperature sensor and different measurement data of the temperature of the second stratum from the second temperature sensor of the first temperature probe.
9. The battery module of claim 8 , wherein the multiple-zone battery module temperature monitoring system further comprises:
a second temperature probe disposed at a second location of the battery module spaced apart from the first location in an area between three or more different immediately adjacent battery cells in the array of battery cells, the second temperature probe comprising a first temperature sensor disposed adjacent to a first probe end of the second temperature probe and a second temperature sensor spaced apart from the first temperature sensor and disposed adjacent to a second probe end of the second temperature probe.
10. The battery module of claim 9 , wherein the processor receives data from the first temperature sensor and the second temperature sensor of the second temperature probe, wherein the data from the first temperature sensor of the second temperature probe corresponds to a temperature measurement in a first stratum associated with first ends of the three or more different immediately adjacent battery cells in the array of battery cells, and wherein the data from the second temperature sensor of the second temperature probe corresponds to a temperature measurement in a second stratum associated with opposite second ends of the three or more different immediately adjacent battery cells in the in the array of battery cells.
11. The battery module of claim 10 , wherein the processor determines a difference between the temperature measurements in the first and second strata of the first temperature probe and determines a difference between the temperature measurements in the first and second strata of the second temperature probe.
12. The battery module of claim 11 , wherein the first temperature probe includes an elongated housing extending a length from the first probe end to the second probe end of the first temperature probe, and wherein the second temperature probe includes an elongated housing extending the length from the first probe end to the second probe end of the second temperature probe.
13. The battery module of claim 12 , wherein the first and second temperature sensors of the first and second temperature probes are disposed at least partially within the elongated housing of the first and second temperature probes, respectively, and wherein the second probe ends of the first and second temperature probes are adjacent to positive terminals of the three or more immediately adjacent battery cells in the array of battery cells and the three or more different immediately adjacent battery cells in the array of battery cells, respectively.
14. The battery module of claim 13 , wherein the first and second temperature probes are electrically interconnected via a flexible printed circuit substrate running from the second probe ends of the first and second temperature probes to the processor.