Integrated string control unit systems and methods

• US 10,148,102 B2
• Filed: 08/31/2016
• Issued: 12/04/2018
• Est. Priority Date: 11/04/2015
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Dulle, Ronald J., Gunderson, Mark D., Tosch, Charles S.
• Primary Examiner(s): Wang, Albert
• Application Number:
  US15/253,463
• Publication Number:
  US 20170123471A1
• Time in Patent Office: 825 Days
• CPC Class Codes: B60L 2240/54 related to batteries
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 58/10 for monitoring or controlling batteries
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: B60L 58/21 having the same nominal voltage
• CPC Class Codes: B60L 58/24 for controlling the temperature of batteries
• CPC Class Codes: G01R 31/3835 involving only voltage measurements
• CPC Class Codes: G01R 31/396 Acquisition or processing of data for testing or for monitoring individual cells or groups of cells within a battery
• CPC Class Codes: G06F 1/266 Arrangements to supply power to external peripherals either directly from the computer or under computer control, e.g. supply of power through the communication port, computer controlled power-strips
• CPC Class Codes: G06F 1/3212 Monitoring battery levels, e.g. power saving mode being initiated when battery voltage goes below a certain level
• CPC Class Codes: G06F 30/13 Architectural design, e.g. computer-aided architectural design [CAAD] related to design of buildings, bridges, landscapes, production plants or roads
• CPC Class Codes: G06F 30/15 Vehicle, aircraft or watercraft design
• CPC Class Codes: H01M 10/42 Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells H01M10/60 takes precedence
• CPC Class Codes: H01M 10/4207 for several batteries or cells simultaneously or sequentially
• 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 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 10/482 : for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 2010/4271 : Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/249 : specially adapted for aircraft or vehicles, e.g. cars or trains constructional details of batteries specially adapted for electric vehicles B60L50/64
• CPC Class Codes: H01M 50/574 : Devices or arrangements for the interruption of current
• CPC Class Codes: H02J 2310/48 : for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 7/0031 : using battery or load disconnect circuits H02J9/002 takes precedence
• CPC Class Codes: H04L 67/12 : specially adapted for proprietary or special-purpose networking environments, e.g. medical networks, sensor networks, networks in vehicles or remote metering networks
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles

Abstract

One embodiment of the present disclosure describes a battery system that includes a battery string with a first and second battery module connected in series; and a battery control system that includes a cell control unit electrically coupled to the first battery module, in which the first cell control unit determines first module level operational parameters related to operation of the first battery module; an integrated string control unit electrically coupled to the second battery module, in which the integrated string control unit determines second module level operational parameters related to operation of the second battery module; determines string level operational parameters related to operation of the battery string based at least in part on the first module level operational parameters and the second module level operational parameters; and controls operation of the battery string based at least in part on the string level operational parameters.

Claims

1. A battery system comprising:

a first battery string comprising a first battery module and a second battery module connected in series;

a battery control system configured to control operation of the battery system, wherein the battery control system comprises;

a first cell control unit electrically coupled to the first battery module, wherein the first cell control unit is configured to determine first module level operational parameters related to operation of the first battery module;

a first integrated string control unit communicatively coupled to the first cell control unit and electrically coupled to the second battery module, wherein;

the first integrated string control unit is configured to;

determine second module level operational parameters related to operation of the second battery module;

determine first string level operational parameters related to operation of the first battery string based at least in part on the first module level operational parameters and the second module level operational parameters; and

control operation of the first battery string based at least in part on the first string level operational parameters; and

the first integrated string control unit comprises;

an integrated cell control unit configured to operate using first high voltage electrical power received from the second battery module and to determine the second module level operational parameters based at least in part on the first high voltage electrical power;

a communication interface configured to operate using low voltage electrical power received from an external power source;

processing circuitry and a processing unit configured to operate using second high voltage electrical power; and

an isolation barrier formed to electrically isolate the processing circuitry and the processing unit from the communication interface, wherein the isolation barrier comprises;

 

an isolated communication interface configured to communicatively couple the processing circuitry and the processing unit with the communication interface through the isolation barrier; and

 

a transformer configured to receive the low voltage electrical power form the external power source and generate the second high voltage electrical power supplied to the processing circuitry and the processing unit based at least in part on the low voltage electrical power.

2. The battery system of claim 1, wherein:

the first battery string comprises a third battery module connected in series with the first battery module and the second battery module; and

the battery control system comprises a second cell control unit electrically coupled to the third battery module and communicatively coupled to the first integrated string control unit, wherein the second cell control unit is configured to determine third module level operational parameters related to operation of the third battery module; and

the first integrated string control unit is configured to determine the first string level operational parameters based at least in part on the third module level operational parameters.

3. The battery system of claim 1, comprising a second battery string, wherein:

the second battery string comprises a third battery module and a fourth battery module connected in series; and

the battery control system comprises;

a second cell control unit electrically coupled to the third battery module, wherein the second cell control unit is configured to determine third module level operational parameters related to operation of the third battery module; and

a second integrated string control unit communicatively coupled to the second cell control unit and electrically coupled to the fourth battery module, wherein the second integrated string control unit is configured to;

determine fourth module level operational parameters related to operation of the fourth battery module;

determine second string level operational parameters related to operation of the second battery string based at least in part on the third module level operational parameters and the fourth module level operational parameters; and

control operation of the second battery string based at least in part on the second string level operational parameters.

4. The battery system of claim 3, comprising:

a positive bus and a negative bus configured to electrically couple the battery system to an electrical load, an electrical source, or both; and

a battery chain comprising the first battery string and the second battery string connected in series between the positive bus and the negative bus;

wherein the second integrated string control unit is communicatively coupled to the first integrated string control unit via a serial communication network.

5. The battery system of claim 3, wherein:

the second integrated string control unit is configured to determine whether a fault is detected in the second battery string; and

the first integrated string control unit is configured to instruct a relay to disconnect the battery chain from the battery system.

6. The battery system of claim 1, wherein the processing circuitry and the processing unit are configured to receive the second high voltage electrical power from the battery string when supply of the low voltage electrical power to the first integrated string control unit is disrupted.

7. The battery system of claim 1, wherein:

the first battery module comprises a first battery cell group and a second battery cell group, wherein the first battery cell group comprises a first plurality of battery cells and the second battery cell group comprises a second plurality of battery cells;

the first cell control unit, to determine the first module level operational parameters, is configured to;

determine a first cell group voltage of the first battery cell group;

determine a second cell group voltage of the second battery cell group; and

determine a first battery module voltage of the first battery module;

the second battery module comprises a third battery cell group and a fourth battery cell group, wherein the third battery cell group comprises a third plurality of battery cells and the fourth battery cell group comprises a fourth plurality of battery cells;

the first integrated string control unit, to determine the second module level operational parameters, is configured to;

determine a third cell group voltage of the third battery cell group;

determine a fourth cell group voltage of the fourth battery cell group; and

determine a second battery module voltage of the second battery module; and

the first integrated string control unit, to determine the first string level operational parameters, is configured to

determine a string voltage of the first battery string based at least in part on the first cell group voltage, the second cell group voltage, the first battery module voltage, the third cell group voltage, the fourth cell group voltage, the second battery module voltage, or any combination thereof; and

determine a string current of the first battery string based at least in part on electrical power supplied to the first integrated string control unit from the first battery string.

8. The battery system of claim 1, wherein:

the first battery module comprises;

a first plurality of battery cells; and

a first housing configured to house the first plurality of battery cells, wherein the first cell control unit is disposed directly on a first surface of the first housing;

the second battery module comprises;

a second plurality of battery cells; and

a second housing configured to house the second plurality of battery cells, wherein the first integrated string control unit is disposed directly on a second surface of the second housing.

9. A method for implementing a battery control system used to control operation of a battery system, comprising:

implementing a first cell control unit by electrically coupling the first cell control unit to a first terminal of a first battery module in the battery system to enable the first cell control unit to receive first high voltage electrical power from the first battery module and to determine first operational parameters related to operation of the first battery module; and

implementing a first integrated string control unit by;

electrically coupling the first integrated string control unit to a second terminal of a second battery module in the battery system to enable the first integrated string control unit to receive second high voltage electrical power from a first battery string and to determine second operational parameters related to operation of the second battery module, wherein the first battery string comprises the first battery module and the second battery module connected in series; and

communicatively coupling the first integrated string control unit to the first cell control unit via a first high voltage serial communication network to enable the first integrated string control unit to determine third operational parameters related to operation of the first battery string based at least in part on the first operational parameters and to determine control commands instructing the battery system to adjust operation of the first battery string.

10. The method of claim 9, wherein:

implementing the first cell control unit comprises;

communicatively coupling a first analog-to-digital converter to a first sensor communication interface to enable the first cell control unit to receive a first analog representation of first sensor data from a first sensor and to generate a first digital representation of the first sensor data;

communicatively coupling logic circuitry to the first analog-to-digital converter to enable the logic circuitry to perform a logic operation, an arithmetic operation, or both based at least in part on the first digital representation of the first sensor data; and

communicatively coupling a first serial communication interface to the logic circuitry to enable the first cell control unit to communicate data with the first integrated string control unit via the first high voltage serial communication network; and

implementing the first integrated string control unit comprises;

communicatively coupling a second analog-to-digital converter to a second sensor communication interface to enable the first integrated string control unit to receive a second analog representation of second sensor data from a second sensor and to generate a second digital representation of the second sensor data; and

communicatively coupling processing circuitry, a processing unit, or both to the second analog-to-digital converter to enable the first integrated string control unit to determine the third operational parameters, determine the control commands, or both based at least in part on the second digital representation.

11. The method of claim 10, wherein implementing the first integrated string control unit comprises:

communicatively coupling a first communication interface to the processing circuitry, the processing unit, or both to enable the first integrated string control unit to communicate data with the first cell control unit via the first high voltage serial communication network;

forming an isolation barrier to electrically isolate the processing circuitry, the processing unit, and the first communication interface from a second communication interface, wherein the isolation barrier comprises an isolated communication interface;

communicatively coupling the processing circuitry, the processing unit, or both to a first end of the isolated communication interface; and

communicatively coupling the second communication interface to a second end of the isolated communication interface to enable the first integrated string control unit to communicate data within the battery control system via a low voltage serial communication network, a low voltage parallel communication network, or both.

12. The method of claim 10, wherein implementing the first integrated string control unit comprises:

forming an isolation barrier comprising a transformer;

electrically coupling a low voltage power source to a first end of the transformer to enable the transformer to receive low voltage electrical power from the low voltage power source; and

electrically coupling the processing circuitry, the processing unit, or both to a second end of the transformer to enable the transformer to generate a third high voltage electrical power supplied to operate the processing circuitry, the processing unit, or both.

13. The method of claim 9, comprising implementing a second cell control unit by electrically coupling the second cell control unit to a third terminal of a third battery module to enable the second cell control unit to receive third high voltage electrical power from the third battery module and to determine fourth operational parameters related to operation of the third battery module, wherein the first battery string comprises the third battery module connected in series with the first battery module and the second battery module;

wherein implementing the first integrated string control unit comprises communicatively coupling the first integrated string control unit to the second cell control unit via the first high voltage serial communication network to enable the first integrated string control unit to determine the third operational parameters based at least in part on the fourth operational parameters.

14. The method of claim 9, comprising:

implementing a second cell control unit by electrically coupling the second cell control unit to a third terminal of a third battery module in the battery system to enable the second cell control unit to receive third high voltage electrical power from the third battery module and to determine fourth operational parameters related to operation of the third battery module; and

implementing a second integrated string control unit by;

electrically coupling the second integrated string control unit to a fourth terminal of a fourth battery module in the battery system to enable the second integrated string control unit to receive fourth high voltage electrical power from a second battery string and to determine fifth operational parameters related to operation of the fourth battery module, wherein the second battery string comprises the third battery module and the fourth battery module connected in series; and

communicatively coupling the second integrated string control unit to the second cell control unit via a second high voltage serial communication network to enable the second integrated string control unit to determine sixth operational parameters related to operation of the second battery string based at least in part on the fourth operational parameters.

15. The method of claim 14, comprising:

implementing a chain control unit by coupling the chain control unit to the first integrated string control unit to enable the chain control unit to determine seventh operational parameters of a battery chain, wherein the battery chain comprises the first battery string and the second battery string connected in series; and

implementing a system control unit by communicatively coupling the system control unit to the first integrated string control unit and the second integrated string control unit via a parallel communication network;

wherein implementing the second integrated string control unit comprises communicatively coupling the second integrated string control unit to the first integrated string control unit via a low voltage serial communication network.

16. The method of claim 9, wherein implementing the first integrated string control unit comprises electrically coupling the first integrated string control unit to the second terminal of the second battery module to enable the first integrated string control unit to determine current flowing in the first battery string.

17. A tangible, non-transitory, computer-readable medium that stores instructions executable by one or more processors of a design system, wherein the instructions comprise instructions to:

determine, using the one or more processors, a battery control system architecture that specifies building blocks used to implement a battery control system in a battery system, wherein the building blocks comprise a cell control unit and an integrated string control unit;

determine, using the one or more processors, number of battery modules in a battery string of the battery system, wherein the battery string comprises one or more battery modules connected in series;

indicating, using the one or more processors, the integrated string control unit to be electrically coupled to a first battery module in the battery string to enable the integrated string control unit to determine a first battery module voltage and a battery string voltage based at least in part on the first battery module voltage; and

indicating, using the one or more processors, the cell control unit to be electrically coupled to a second battery module in the battery string to enable the cell control unit to determine a second battery module voltage only when the battery string comprises multiple battery modules.

18. The computer-readable medium of claim 17, comprising indicating, using the one or more processors, the cell control unit to be communicatively coupled to the integrated string control unit to enable the integrated string control unit to determine the battery string voltage based at least in part on the second battery module voltage only when the battery string comprises multiple battery modules.

19. The computer-readable medium of claim 17, comprising indicating, using the one or more processors, the integrated string control module to be physically coupled to a housing of the first battery module.

20. A battery system comprising:

a first battery string comprising a first battery module and a second battery module connected in series;

a battery control system configured to control operation of the battery system, wherein the battery control system comprises;

a first cell control unit electrically coupled to the first battery module, wherein the first cell control unit is configured to determine first module level operational parameters related to operation of the first battery module;

a first integrated string control unit communicatively coupled to the first cell control unit and electrically coupled to the second battery module, wherein;

the first integrated string control unit is configured to;

determine second module level operational parameters related to operation of the second battery module;

determine first string level operational parameters related to operation of the first battery string based at least in part on the first module level operational parameters and the second module level operational parameters; and

control operation of the first battery string based at least in part on the first string level operational parameters; and

the first integrated string control unit comprises;

a parallel communication interface configured to communicatively couple the first integrated string control unit to a second integrated string control unit and a system control unit via a parallel communication network;

a low voltage serial communication interface configured to communicatively couple the first integrated string control unit to the second integrated string control unit and the system control unit via a low voltage serial communication network;

a high voltage serial communication interface configured to communicatively couple the first integrated string control unit to the first cell control unit via a high voltage serial communication network; and

an isolation barrier configured to electrically isolate the parallel communication interface and the low voltage serial communication interface from the high voltage serial communication interface.