Dual function battery system and method

• US 10,106,038 B2
• Filed: 08/29/2013
• Issued: 10/23/2018
• Est. Priority Date: 12/28/2012
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Jiang, Junwei, Hurley, Patrick T., Wyatt, Perry M., Watson, Thomas M.
• Primary Examiner(s): Fureman, Jared
• Assistant Examiner(s): Dominique, Emmanuel R
• Application Number:
  US14/013,392
• Publication Number:
  US 20140183939A1
• Time in Patent Office: 1,881 Days
• Field of Search: 307 9
• CPC Class Codes: B60L 1/08 Methods and devices for control or regulation
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 2260/26 Transition between different drive modes
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 58/13 Maintaining the SoC within a determined range
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: B60L 7/10 Dynamic electric regenerative braking B60L7/22 takes precedence
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 2010/4278 Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 4/131 Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
• CPC Class Codes: H01M 4/136 Electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy
• CPC Class Codes: H02J 7/0014 Circuits for equalisation of charge between batteries
• CPC Class Codes: H02J 7/0024 Parallel/serial switching of connection of batteries to charge or load circuit
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

An energy storage system for supporting dual electrical functions of a vehicle includes an energy storage unit having a plurality of energy storage modules connected in series, a plurality of sensing units for sensing state of charges of the plurality of energy storage modules, and a pair of primary voltage terminals. The series connected plurality of energy storage modules is connectable across the pair of primary voltage terminals during a key-on state of the vehicle to supply energy storage power at a first voltage level to support primary electrical functions of the vehicle. The energy storage system is further configured to select a subset of the plurality of energy storage modules during a key-off state of the vehicle to connect across a pair of secondary voltage terminals using a switch network to supply energy storage power at a second voltage level.

Claims

1. An energy storage system for a vehicle, comprising:

an energy storage unit having a plurality of energy storage modules connected in series;

a plurality of sensing units coupled to the plurality of energy storage modules, wherein each of the plurality of sensing units is configured to sense a state of a respective energy storage module, and wherein the sensed state enables an estimation of a respective state of charge of the respective energy storage module;

a pair of primary voltage terminals connected to the plurality of energy storage modules and configured to supply energy storage power from the plurality of energy storage modules at a first voltage level to support primary electrical functions of the vehicle;

a pair of secondary voltage terminals; and

a controller configured to;

select, via operation of a switching network, a first energy storage module of the plurality of energy storage modules to connect across the pair of secondary voltage terminals to supply energy storage power to an accessory load of the vehicle at a second voltage level lower than the first voltage level;

estimate a first state of charge of the first energy storage module;

automatically disconnect the first energy storage module from the pair of secondary voltage terminals in response to the first state of charge being below a requested state of charge associated with the accessory load;

estimate a second state of charge of a second energy storage module of the plurality of energy storage modules; and

connect the second energy storage module of the plurality of energy storage modules across the pair of secondary voltage terminals when the second state of charge is greater than the requested state of charge.

2. The energy storage system of claim 1, wherein:

each of the plurality of energy storage modules has a positive pole and a negative pole;

the pair of secondary voltage terminals includes a positive terminal and a negative terminal;

the controller controls the switching network that includes a first plurality of switches, wherein each switch of the first plurality of switches is connected between a respective positive pole of the plurality of energy storage modules and the positive terminal of the pair of secondary voltage terminals, and a second plurality of switches, wherein each switch of the second plurality of switches is connected between a respective negative pole of the plurality of energy storage modules and the negative terminal of the pair of secondary voltage terminals; and

an activation unit for selectively turning on associated pairs of the first plurality of switches and the second plurality of switches respectively connected to the positive and negative poles of the plurality of energy storage modules.

3. The energy storage system of claim 1, wherein each of the plurality of energy storage modules has one or more cells connected in series or parallel.

4. The energy storage system of claim 1, further comprising a key-off detector configured to detect when a key of the vehicle has been turned to a key-off position, and wherein, in response to a key-off detection, the controller is configured to selectively connect one of the plurality of energy storage modules across the pair of secondary voltage terminals to provide power to a key-off accessory of the vehicle.

5. The energy storage system of claim 1, wherein each of the plurality of energy storage modules has an equal number of energy storage cells, wherein each of the equal number of energy storage cells is configured to produce approximately the same voltage, a plurality of energy storage cells connected in series, a plurality of cells connected in parallel, at least one energy storage cell with chemistry of one of (a) NCA, (b) NMC, (c) LiMn2O4, and (d) a blend of the chemistries of (a), (b), and (c), wherein the plurality of cells comprise:

cathode material having cell chemistry that is olivine based material;

cathode material made of LiFe1-xPO4 in which x is greater than or equal to zero and less than or equal to one; and

cells with cathode material that is made of olivine material Zx doped LiFePO4, in which x is greater than or equal to zero and less than or equal to one.

6. The energy storage system of claim 1, wherein the first energy storage module has a different number of energy storage cells than that of the second energy storage module.

7. A computer-implemented method for performing dual functions of an energy storage system in a vehicle, comprising:

providing stored electrical power for supporting primary electrical functions of the vehicle during a key-on state at a pair of primary voltage terminals of the energy storage system having a plurality of energy storage modules connected in series across the pair of primary voltage terminals;

detecting when the vehicle has been turned off;

during an off state, providing the stored electrical power from a reduced number of the plurality of energy storage modules for supporting secondary electrical functions of the vehicle, thereby operating key-off loads of the vehicle at a pair of secondary voltage terminals by connecting the reduced number of the plurality of energy storage modules via operation of a switching network across the pair of secondary voltage terminals while maintaining the plurality of energy storage modules connected in series across the pair of primary voltage terminals;

estimating a first state of charge of one of the reduced number of the plurality of energy storage modules connected across the pair of secondary voltage terminals;

determining whether the one of the reduced number of the plurality of energy storage modules should be disconnected from the pair of secondary voltage terminals and whether one of a remainder of the plurality of energy storage modules not initially included in the reduced number of the plurality of energy storage modules should be connected across the pair of secondary voltage terminals based on the first state of charge of the one of the reduced number of the plurality of energy storage modules;

disconnecting the one of the reduced number of the plurality of energy storage modules from the pair of secondary voltage terminals in response to a difference between the first state of charge and a preselected state of charge level being less than a predetermined value;

estimating a second state of charge of the one of the remainder of the plurality of energy storage modules; and

connecting the one of the remainder of the plurality of energy storage modules to the pair of secondary voltage terminals in response to a difference between the second state of charge and the preselected state of charge level being greater than the predetermined value.

8. The computer-implemented method of claim 7, further comprising:

controlling the switching network to successively connect each energy storage module of the plurality of energy storage modules across the pair of secondary voltage terminals, wherein each energy storage module becomes part of the reduced number of the plurality of energy storage modules when connected.

9. The computer-implemented method of claim 7, further comprising:

establishing a preselected order of succession in which the each of the plurality of energy storage modules are successively connected across the pair of secondary voltage terminals, wherein each of the plurality of energy storage modules becomes part of the reduced number of the plurality of energy storage modules when connected.

10. The computer-implemented method of claim 9, further comprising:

detecting a key-off state of the vehicle using a key-off detector;

determining which one of the key-off loads requires a supply of power while the vehicle is not operating; and

selecting one of the plurality of energy storage modules for connection across the pair of secondary voltage terminals to provide stored energy power to the one of the key-off loads.

11. The computer-implemented method of claim 10, further comprising:

providing stored energy from the pair of secondary voltage terminals to a vehicle accessory load that requires power when the vehicle is being operated.

12. The computer-implemented method of claim 7, wherein each of the plurality of energy storage modules has one or more electrochemical or electrostatic cells connected in series or parallel.

13. The computer-implemented method of claim 8, wherein the switching network includes a first plurality of switches individually connected between a respective positive pole of the plurality of energy storage modules and a positive terminal of the pair of secondary voltage terminals, and a second plurality of switches individually connected between a respective negative pole of the plurality of energy storage modules and a negative terminal of the pair of secondary voltage terminals.

14. The computer-implemented method of claim 13, further comprising:

an activation unit for selectively turning on or off associated pairs of the first plurality of switches and the second plurality of switches respectively connected to the positive and negative poles of the plurality of energy storage modules.

15. A computing system, comprising:

at least one processing unit and at least one memory unit storing instructions that are operable, when executed by the at least one processing unit, to cause the at least one processing unit to perform a method for performing dual functions of an energy storage system in a vehicle, the method comprising;

providing stored electrical power for supporting primary electrical functions of the vehicle during a key-on state at a pair of primary voltage terminals of the energy storage system having a plurality of energy storage modules connected in series across the pair of primary voltage terminals;

detecting when the vehicle has been turned off;

during an off state, providing stored electrical power from a reduced number of the plurality of energy storage modules for supporting secondary electrical functions of the vehicle, thereby operating key-off loads of the vehicle at a pair of secondary voltage terminals by connecting the reduced number of the plurality of energy storage modules via operation of a switching network across the pair of secondary voltage terminals while maintaining the plurality of energy storage modules connected in series across the pair of primary voltage terminals;

estimating a first state of charge of one of the reduced number of the plurality of energy storage modules connected across the pair of secondary voltage terminals;

determining whether the one of the reduced number of the plurality of energy storage modules should be disconnected from the pair of secondary voltage terminals and whether one of a remainder of the plurality of energy storage modules not initially included in the reduced number of the plurality of energy storage modules should be connected across the pair of secondary voltage terminals based on the first state of charge of the one of the reduced number of the plurality of energy storage modules;

disconnecting the one of the reduced number of the plurality of energy storage modules from the pair of secondary voltage terminals in response to a difference between the first state of charge and a preselected state of charge level being less than a predetermined value

estimating a second state of charge of the one of the remainder of the plurality of energy storage modules; and

connecting the one of the remainder of the plurality of energy storage modules to the pair of secondary voltage terminals in response to a difference between the second state of charge and the preselected state of charge level being greater than the predetermined value.

16. The computing system of claim 15, further comprising:

controlling the switching network to successively connect each of the plurality of energy storage modules across the pair of secondary voltage terminals.