Charging a lithium battery on a utility vehicle

• US 10,195,953 B2
• Filed: 01/30/2017
• Issued: 02/05/2019
• Est. Priority Date: 12/30/2016
• Status: Active Grant

• Current Assignee: Textron Innovations Incorporated (Textron Inc)
• Original Assignee: Textron Innovations Incorporated (Textron Inc)
• Inventors: Harvey, Arthur James, Padgett, Norman R., Ledden, John
• Primary Examiner(s): Dinh, Paul
• Application Number:
  US15/419,556
• Publication Number:
  US 20180186244A1
• Time in Patent Office: 736 Days
• Field of Search: 320109
• CPC Class Codes: B60L 2200/22 Microcars, e.g. golf cars
• CPC Class Codes: B60L 2200/40 Working vehicles
• CPC Class Codes: B60L 2200/44 Industrial trucks or floor conveyors
• CPC Class Codes: B60L 2220/50 Structural details of electrical machines
• 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 2240/80 Time limits
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/30 Constructional details of charging stations
• CPC Class Codes: B60L 53/305 Communication interfaces
• CPC Class Codes: B60L 53/62 in response to charging parameters, e.g. current, voltage or electrical charge
• CPC Class Codes: B60L 58/12 responding to state of charge [SoC]
• 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: 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: H02J 7/0036 using connection detecting circuits H02J7/0034 takes precedence
• CPC Class Codes: H02J 7/0045 : concerning the insertion or the connection of the batteries
• CPC Class Codes: Y02P 90/60 : Electric or hybrid propulsion means for production processes
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 : Electric charging stations
• 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

A charging system charges a lithium battery of a utility vehicle. The charging system includes a receptacle configured to couple with an external charger, a lithium battery configured to provide lithium battery power to a set of electrical loads of the utility vehicle, and control circuitry coupled with the receptacle and the lithium battery. The control circuitry is configured to detect connection between the external charger and the receptacle and, in response to detecting connection between the external charger and the receptacle, ascertain a charging state of the lithium battery. The control circuitry is further configured to output, based on the charging state, a control signal to the external charger through the receptacle, the control signal being configured to control charging output from the external charger to charge the lithium battery.

Claims

1. A charging system for charging a lithium battery of a utility vehicle, the charging system comprising:

a receptacle configured to couple with an external charger;

a lithium battery configured to provide lithium battery power to a set of electrical loads of the utility vehicle; and

control circuitry coupled with the receptacle and the lithium battery, the control circuitry being configured to;

detect connection between the external charger and the receptacle,

in response to detecting connection between the external charger and the receptacle, ascertain a charging state of the lithium battery, and

based at least in part on the charging state, provide a control signal to the external charger through the receptacle, the control signal being configured to control charging output from the external charger to charge the lithium battery;

wherein the control circuitry is further configured to;

detect a fully charged state of the lithium battery, and

in response to detecting the fully charged state of the lithium battery, provide, as the control signal, a command configured to (i) inform the external charger that the lithium battery is fully charged and (ii) direct the external charger to terminate charging;

wherein the control circuitry includes;

a lithium battery management system (BMS) coupled with the lithium battery and the receptacle, the lithium BMS having a contactor configured to close to provide electrical access to the lithium battery and open to remove electrical access to the lithium battery, the lithium BMS opening the contactor in response to detecting the fully charged state of the lithium battery;

wherein the lithium BMS includes;

an inactivity timer, and

control logic coupled with the timer and the contactor, the control logic being configured to (i) start the inactivity timer in response to the lithium BMS reaching the fully charged state and (ii) in response to expiration of the inactivity timer and in the absence of sensed electronic activity by the utility vehicle, open the contactor to remove electrical access to the lithium battery.

2. A charging system as in claim 1 wherein the control circuitry further includes:

detection circuitry coupled with the lithium BMS, the detection circuitry being configured to (i) detect connection between the external charger and the receptacle and (ii) in response to detecting connection between the external charger and the receptacle, notify the lithium BMS that there is connection between the external charger and the receptacle.

3. A charging system as in claim 2 wherein the detection circuitry is further configured to:

detect disconnection of the external charger from the receptacle, and

in response to detecting disconnection of the external charger from the receptacle, notify the lithium BMS that the external charger is disconnected from the receptacle.

4. A charging system as in claim 1 wherein the lithium battery includes a set of lithium cell modules;

and

wherein the control circuitry is configured to;

receive a set of temperature measurements from the set of lithium cell modules, the set of temperature measurements identifying at least a portion of the charging state of the lithium battery, and

provide the control signal further based on the set of temperature measurements.

5. A charging system as in claim 1 wherein the utility vehicle includes a vehicle body;

and

wherein the receptacle, the lithium battery, and the control circuitry are part of the utility vehicle and are supported by the vehicle body.

6. A charging system as in claim 1 wherein the contactor is part of the utility vehicle and is separate from the external charger.

7. A charging system as in claim 1 wherein the control circuitry is part of the utility vehicle and is interconnected between the receptacle and the lithium battery.

8. A charging system as in claim 1 wherein the utility vehicle includes a vehicle body;

wherein the receptacle, the lithium battery, and the control circuitry are part of the utility vehicle and are supported by the vehicle body;

wherein the contactor is part of the utility vehicle and is external to the external charger; and

wherein the control circuitry is part of the utility vehicle and is interconnected between the receptacle and the lithium battery.

9. A charging system for charging a lithium battery of a utility vehicle, the charging system comprising:

a receptacle configured to couple with an external charger;

a lithium battery configured to provide lithium battery power to a set of electrical loads of the utility vehicle; and

control circuitry coupled with the receptacle and the lithium battery, the control circuitry being configured to;

detect connection between the external charger and the receptacle,

in response to detecting connection between the external charger and the receptacle, ascertain a charging state of the lithium battery, and

based at least in part on the charging state, provide a control signal to the external charger through the receptacle, the control signal being configured to control charging output from the external charger to charge the lithium battery;

wherein the control circuitry includes;

a lithium battery management system (BMS) coupled with the lithium battery and the receptacle, the lithium BMS having a contactor configured to close to provide electrical access to the lithium battery and open to remove electrical access to the lithium battery;

wherein the control circuitry further includes;

detection circuitry coupled with the lithium BMS, the detection circuitry being configured to (i) detect connection between the external charger and the receptacle and (ii) in response to detecting connection between the external charger and the receptacle, notify the lithium BMS that there is connection between the external charger and the receptacle;

wherein the detection circuitry is further configured to;

detect disconnection of the external charger from the receptacle, and

in response to detecting disconnection of the external charger from the receptacle, notify the lithium BMS that the external charger is disconnected from the receptacle;

wherein the detection circuitry forms part of a motor controller of the utility vehicle, the motor controller being configured to;

control operation of an electric motor of the utility vehicle, and

communicate with the lithium BMS through a controller area network (CAN) bus; and

wherein the detection circuitry is configured to;

provide on multiple instances, while the external charger is connected with the receptacle, a first CAN message to the lithium BMS through the CAN bus to notify the lithium BMS that there is connection between the external charger and the receptacle, and

provide a second CAN message to the lithium BMS through the CAN bus to notify the lithium BMS that the external charger is disconnected from the receptacle, the first CAN message being different from the second CAN message.

10. A charging system for charging a lithium battery of a utility vehicle, the charging system comprising:

a receptacle configured to couple with an external charger;

a lithium battery configured to provide lithium battery power to a set of electrical loads of the utility vehicle; and

control circuitry coupled with the receptacle and the lithium battery, the control circuitry being configured to;

detect connection between the external charger and the receptacle,

in response to detecting connection between the external charger and the receptacle, ascertain a charging state of the lithium battery, and

based at least in part on the charging state, provide a control signal to the external charger through the receptacle, the control signal being configured to control charging output from the external charger to charge the lithium battery;

wherein the control circuitry includes;

a lithium battery management system (BMS) coupled with the lithium battery and the receptacle, the lithium BMS having a contactor configured to close to provide electrical access to the lithium battery and open to remove electrical access to the lithium battery;

wherein the control circuitry further includes;

detection circuitry coupled with the lithium BMS, the detection circuitry being configured to (i) detect connection between the external charger and the receptacle and (ii) in response to detecting connection between the external charger and the receptacle, notify the lithium BMS that there is connection between the external charger and the receptacle;

wherein the detection circuitry is further configured to;

detect disconnection of the external charger from the receptacle, and

in response to detecting disconnection of the external charger from the receptacle, notify the lithium BMS that the external charger is disconnected from the receptacle;

wherein the motor controller is configured to control power delivery to an electric brake of the utility vehicle, the electric brake being configured to (i) provide mechanical resistance which inhibits a motor of the utility vehicle from turning when the electric brake is unpowered and (ii) remove the mechanical resistance to allow the motor of the utility vehicle to turn when power is provided to the electric brake; and

wherein the detection circuitry is configured to prevent the motor controller from delivering power to the electric brake to keep the utility vehicle in place while there is connection between the external charger and the receptacle.

11. A charging system for charging a lithium battery of a utility vehicle, the charging system comprising:

a receptacle configured to couple with an external charger;

a lithium battery configured to provide lithium battery power to a set of electrical loads of the utility vehicle; and

control circuitry coupled with the receptacle and the lithium battery, the control circuitry being configured to;

detect connection between the external charger and the receptacle,

in response to detecting connection between the external charger and the receptacle, ascertain a charging state of the lithium battery, and

based at least in part on the charging state, provide a control signal to the external charger through the receptacle, the control signal being configured to control charging output from the external charger to charge the lithium battery;

wherein the lithium battery includes a set of lithium cell modules;

wherein the control circuitry is configured to;

receive a set of temperature measurements from the set of lithium cell modules, the set of temperature measurements identifying at least a portion of the charging state of the lithium battery, and

provide the control signal further based on the set of temperature measurements; and

wherein the control circuitry, when providing the control signal further based on the set of temperature measurements, is configured to;

receive, as a current set of measurements, a minimum temperature measurement and a maximum temperature measurement from each lithium cell module,

identify an overall minimum temperature measurement and an overall maximum temperature measurement from the current set of measurements, and

provide, as the control signal, (i) a first command when the overall minimum temperature measurement and the overall maximum temperature measurement are within a predefined normal temperature range, and (ii) another command that is different from the first command when at least one of the overall minimum temperature measurement and the overall maximum temperature measurement falls outside the predefined normal temperature range.

12. A charging system as in claim 11 wherein the control circuitry, when providing the other command that is different from the first command, is configured to:

provide, as the other command, (i) a second command when the overall minimum temperature measurement and the overall maximum temperature measurement are within a predefined suboptimal temperature range which is outside the predefined normal temperature range, and (ii) third command when at least one of the overall minimum temperature measurement and the overall maximum temperature measurement falls outside the predefined suboptimal temperature range.

13. A charging system as in claim 12 wherein the first command is configured to direct the external charger to charge the lithium battery at a normal rate;

wherein the second command is configured to direct the external charger to charge the lithium battery at a slow rate which is slower than the normal rate; and

wherein the third command is configured to direct the external charger to not charge the lithium battery.

14. A charging system as in claim 13 wherein each of the first command, the second command, and the third command is a different pulse width modulation (PWM) signal to imitate electrical behavior of a thermistor.

15. A charging system as in claim 12 wherein the first command is further configured to direct the external charger to flash a light emitting diode (LED) of the receptacle at a first speed to indicate charging at the normal rate;

wherein the second command is further configured to direct the external charger to flash the LED of the receptacle at a second speed which is different from the first speed to indicate charging at the slow rate;

wherein the third command is further configured to direct the external charger not to flash the LED to indicate that the charger is not charging the lithium battery.

16. A utility vehicle, comprising:

a utility vehicle body;

a set of electrical loads supported by the utility vehicle body; and

a charging system supported by the utility vehicle body and coupled with the set of electrical loads, the charging system including;

a receptacle configured to couple with an external charger,

a lithium battery configured to provide lithium battery power to the set of electrical loads, and

control circuitry coupled with the receptacle and the lithium battery, the control circuitry being configured to;

detect connection between the external charger and the receptacle,

in response to detecting connection between the external charger and the receptacle, ascertain a charging state of the lithium battery, and

based at least in part on the charging state, output a control signal to the external charger through the receptacle, the control signal being configured to control charging output from the external charger to charge the lithium battery;

wherein the control circuitry is further configured to;

detect a fully charged state of the lithium battery, and

in response to detecting the fully charged state of the lithium battery, provide, as the control signal, a command configured to (i) inform the external charger that the lithium battery is fully charged and (ii) direct the external charger to terminate charging;

wherein the control circuitry includes;

a lithium battery management system (BMS) coupled with the lithium battery and the receptacle, the lithium BMS having a contactor configured to close to provide electrical access to the lithium battery and open to remove electrical access to the lithium battery, the lithium BMS opening the contactor in response to detecting the fully charged state of the lithium battery;

wherein the lithium BMS includes;

an inactivity timer, and

control logic coupled with the timer and the contactor, the control logic being configured to (i) start the inactivity timer in response to the lithium BMS reaching the fully charged state and (ii) in response to expiration of the inactivity timer and in the absence of sensed electronic activity by the utility vehicle, open the contactor to remove electrical access to the lithium battery.

17. A utility vehicle as in claim 16 wherein the contactor is separate from and external to the external charger.

18. A utility vehicle as in claim 16 wherein the control circuitry is interconnected between the receptacle and the lithium battery.

19. In a utility vehicle, a method of charging a lithium battery, the method comprising:

detecting, by control circuitry of the utility vehicle, connection between an external charger that is external to the utility vehicle and a receptacle of the utility vehicle,

in response to detecting connection between the external charger and the receptacle, ascertaining, by the control circuitry, a charging state of the lithium battery,

based at least in part on the charging state, providing, by the control circuitry, a control signal to the external charger through the receptacle, the control signal being configured to control charging output from the external charger to charge the lithium battery;

detecting, by the control circuitry, a fully charged state of the lithium battery, and

in response to detecting the fully charged state of the lithium battery, providing, as the control signal and by the control circuitry, a command configured to (i) inform the external charger that the lithium battery is fully charged and (ii) direct the external charger to terminate charging;

wherein the control circuitry includes;

a lithium battery management system (BMS) coupled with the lithium battery and the receptacle, the lithium BMS having a contactor configured to close to provide electrical access to the lithium battery and open to remove electrical access to the lithium battery, the lithium BMS opening the contactor in response to detecting the fully charged state of the lithium battery;

wherein the lithium BMS includes;

an inactivity timer, and

control logic coupled with the timer and the contactor, the control logic being configured to (i) start the inactivity timer in response to the lithium BMS reaching the fully charged state and (ii) in response to expiration of the inactivity timer and in the absence of sensed electronic activity by the utility vehicle, open the contactor to remove electrical access to the lithium battery.

20. A method as in claim 19 wherein detecting the connection between the external charger that is external to the utility vehicle and the receptacle of the utility vehicle includes:

receiving, by the lithium battery management system (BMS) of the control circuitry, a communication from a motor controller of the control circuitry, the motor controller being configured to operate a motor of the utility vehicle, and the communication indicating that the external charger is connected to the receptacle.