Systems for determining a voltage out-of-range high condition and a voltage out-of-range low condition of a battery module

• US 10,203,358 B2
• Filed: 12/20/2016
• Issued: 02/12/2019
• Est. Priority Date: 07/19/2016
• Status: Active Grant

• Current Assignee: LG Energy Solution Limited (LG Corporation)
• Original Assignee: LG Chem Limited (LG Corporation)
• Inventors: Katrak, Kerfegar K.
• Primary Examiner(s): Amrany, Adi
• Application Number:
  US15/385,242
• Publication Number:
  US 20180024172A1
• Time in Patent Office: 784 Days
• Field of Search: 307104
• CPC Class Codes: G01R 19/16542 for batteries charge condition monitoring in G01R31/36
• CPC Class Codes: G01R 19/1659 to indicate that the value is within or outside a predetermined range of values (window) G01R19/16514, G01R19/16519, G01R19/16528 and G01R19/16533 take precedence
• CPC Class Codes: G01R 31/385 Arrangements for measuring battery or accumulator variables for monitoring G01R31/382
• 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: G05B 11/01 electric
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/00308 Overvoltage protection
• CPC Class Codes: H02J 7/0031 using battery or load disconnect circuits H02J9/002 takes precedence
• CPC Class Codes: H02J 7/0047 with monitoring or indicating devices or circuits
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

A system for determining a voltage out-of-range high condition of a battery module is provided. A microcontroller determines first, second, and third voltage values from first, second, and third voltage sensors, respectively, coupled to first, second, and third battery cells, respectively; and determines a battery module voltage value based on a fourth signal. The microcontroller sums the first, second, and third voltage values to obtain a battery module high voltage sum value. The microcontroller generates a first control signal to induce a contactor to transition to an open operational position to electrically decouple the battery module from an electrical load, if a difference between the battery module high voltage sum value and the battery module voltage value is greater than or equal to a battery module voltage out-of-range high error value.

Claims

1. A system for determining a voltage out-of-range high condition of a battery module;

the battery module having at least first, second, and third battery cells, comprising;

a microcontroller determining first, second, and third voltage values based on first, second, and third signals, respectively, corresponding to first, second, and third voltage levels, respectively, of the first, second, and third battery cells, respectively;

the microcontroller determining a battery module voltage value based on a fourth signal;

the microcontroller determining whether at least one of the first, second, and third voltage values is greater than a desired maximum cell voltage value;

the microcontroller replacing the at least one of the first, second, and third voltage values that is greater than the desired maximum cell voltage value with a desired cell voltage value, the desired cell voltage value being less than the desired maximum cell voltage value;

the microcontroller summing the first, second, and third voltage values to obtain a battery module high voltage sum value; and

the microcontroller generating a first control signal to induce a contactor to transition to an open operational position to electrically decouple the battery module from an electrical load, if a difference between the battery module high voltage sum value and the battery module voltage value is greater than or equal to a battery module voltage out-of-range high error value indicating the voltage out-of-range high condition, the battery module voltage out-of-range high error value is equal to a square root of a first sum of squares value therein, the first sum of squares value is equal to a sum of first, second, and third battery cell voltage measurement error square values and a battery module voltage measurement error square value.

2. The system of claim 1, wherein the microcontroller generating a first message indicating the voltage out-of-range high condition of the battery module if the difference between the battery module high voltage sum value and the battery module voltage value is greater than or equal to the battery module voltage out-of-range high error value.

3. The system of claim 1, wherein:

the first battery cell voltage measurement error square value is ti al to a square of a measurement error associated with the first voltage level;

the second battery cell voltage measurement error square value is equal to a square of a measurement error associated with the second voltage level; and

the third battery cell voltage measurement error square value is equal to a square of a measurement error associated with the third voltage level.

4. The system of claim 1, wherein the battery module voltage measurement error square value is equal to a square of a measurement error associated with the battery module voltage level.

5. The system of claim 1, further comprising:

a first voltage sensor being electrically coupled to the first battery cell, the first voltage sensor outputting the first signal indicating the first voltage level being output by the first battery cell;

a second voltage sensor being electrically coupled to the second battery cell, the second voltage sensor outputting the second signal indicating the second voltage level being output by the second battery cell;

a third voltage sensor being electrically coupled to the third battery cell, the third voltage sensor outputting the third signal indicating the third voltage level being output by the third battery cell;

a battery module voltage sensor being electrically coupled to the battery module, the battery module voltage sensor outputting the fourth signal indicating the battery module voltage level being output by the battery module; and

the microcontroller operably coupled to the first, second, and third voltage sensors, the battery module voltage sensor, and a memory device;

the memory device having the battery module voltage out-of-range high error value therein.

6. A system for determining a voltage out-of-range high condition of a battery module;

the battery module having at least first, second, and third battery cells, comprising;

a microcontroller determining first, second, and third voltage values based on first, second, and third signals, respectively, corresponding to first, second, and third voltage levels, respectively, of the first, second, and third battery cells, respectively;

the microcontroller determining a battery module voltage value based on a fourth signal;

the microcontroller determining whether at least one of the first, second, and third voltage values is greater than a desired maximum cell voltage value;

the microcontroller replacing the at least one of the first, second, and third voltage values that is greater than the desired maximum cell voltage value with a desired cell voltage value, the desired cell voltage value being less than the desired maximum cell voltage value;

the microcontroller summing the first, second, and third voltage values to obtain a battery module high voltage sum value; and

the microcontroller generating a first control signal to induce a contactor to transition to an open operational position to electrically decouple the battery module from an electrical load, if a difference between the battery module high voltage sum value and the battery module voltage value is greater than or equal to a battery module voltage out-of-range high error value indicating the voltage out-of-range high condition, the battery module voltage out-of-range high error value is equal to a square root of a first sum of squares value therein, the first sum of squares value is equal to a sum of first, second, and third battery cell weighted voltage measurement error square values and a battery module voltage measurement error square value.

7. The system of claim 6, wherein the microcontroller generating a first message indicating the voltage out-of-range high condition of the battery module if the difference between the battery module high voltage sum value and the battery module voltage value is greater than or equal to the battery module voltage out-of-range high error value.

8. The system of claim 6, wherein the first battery cell weighted voltage measurement error square value is not equal to the second and third battery cell weighted voltage measurement error square values;

and the second battery cell weighted voltage measurement error square value is not equal to the first and third battery cell weighted voltage measurement error square values.

9. The system of claim 6, wherein:

the first battery cell weighted voltage measurement error square value is equal to a square of a weighted measurement error associated with the first voltage level;

the second battery cell weighted voltage measurement error square value is equal to a square of a weighted measurement error associated with the second voltage level; and

the third battery cell weighted voltage measurement error square value is equal to a square of a weighted measurement error associated with the third voltage level.

10. The system of claim 6, wherein the battery module voltage measurement error square value is equal to a square of a measurement error associated with the battery module voltage level.

11. The system of claim 6, further comprising:

a first voltage sensor being electrically coupled to the first battery cell, the first voltage sensor outputting the first signal indicating the first voltage level being output by the first battery cell;

a second voltage sensor being electrically coupled to the second battery cell, the second voltage sensor outputting the second signal indicating the second voltage level being output by the second battery cell;

a third voltage sensor being electrically coupled to the third battery cell, the third voltage sensor outputting the third signal indicating the third voltage level being output by the third battery cell;

a battery module voltage sensor being electrically coupled to the battery module, the battery module voltage sensor outputting the fourth signal indicating the battery module voltage level being output by the battery module; and

the microcontroller operably coupled to the first, second, and third voltage sensors, the battery module voltage sensor, and a memory device;

the memory device having the battery module voltage out-of-range high error value therein.

12. A system for determining a voltage out-of-range low condition of a battery module;

the battery module having at least first, second, and third battery cells, comprising;

a microcontroller determining first, second, and third voltage values based on first, second, and third signals, respectively, corresponding to first, second, and third voltage levels, respectively, of the first, second, and third battery cells, respectively;

the microcontroller determining a battery module voltage value based on a fourth signal;

the microcontroller determining whether at least one of the first, second, and third voltage values is less than a desired minimum cell voltage value;

the microcontroller replacing at least one of the first, second, and third voltage values that is less than the desired minimum cell voltage value with a desired cell voltage value, the desired cell voltage value being greater than the desired minimum cell voltage value;

the microcontroller summing the first, second, and third voltage values to obtain a battery module low voltage sum value; and

the microcontroller generating a first control signal to induce a contactor to transition to an open operational position to electrically decouple the battery module from an electrical load, if a difference between the battery module low voltage sum value and the battery module voltage value is greater than or equal to a battery module voltage out-of-range low error value indicating the voltage out-of-range low condition, the battery module voltage out-of-range low error value is equal to a square root of a first sum of squares value therein, the first sum of squares value is equal to a sum of first, second, and third battery cell voltage measurement error square values and a battery module voltage measurement error square value.

13. The system of claim 12, wherein the microcontroller generating a first message indicating the voltage out-of-range low condition of the battery module if the difference between the battery module low voltage sum value and the battery module voltage value is greater than or equal to the battery module voltage out-of-range low error value indicating the voltage out-of-range low condition.

14. The system of claim 12, wherein:

the first battery cell voltage measurement error square value is equal to a square of a voltage measurement error associated with the first voltage level;

the second battery cell voltage measurement error square value is equal to a square of a measurement error associated with the second voltage level; and

the third battery cell voltage measurement error square value is equal to a square of a measurement error associated with the third voltage level.

15. The system of claim 12, wherein the battery module voltage measurement error square value is equal to a square of a measurement error associated with the battery module voltage level.

17. The system of claim 12, further comprising:

a first voltage sensor being electrically coupled to the first battery cell, the first voltage sensor outputting the first signal indicating the first voltage level being output by the first battery cell;

a second voltage sensor being electrically coupled to the second battery cell, the second voltage sensor outputting the second signal indicating the second voltage level being output by the second battery cell;

a third voltage sensor being electrically coupled to the third battery cell, the third voltage sensor outputting the third signal indicating the third voltage level being output by the third battery cell;

a battery module voltage sensor being electrically coupled to the battery module, the battery module voltage sensor outputting the fourth signal indicating the battery module voltage level being output by the battery module; and

the microcontroller operably coupled to the first, second, and third voltage sensors, the battery module voltage sensor, and a memory device;

the memory device having the battery module voltage out-of-range low error value therein.

16. A system for determining a voltage out-of-range low condition of a battery module;

the battery module having at least first, second, and third battery cells, comprising;

a microcontroller determining first, second, and third voltage values based on first, second, and third signals, respectively, corresponding to first, second, and third voltage levels, respectively, of the first, second, and third battery cells, respectively;

the microcontroller further determining a battery module voltage value based on a fourth signal;

the microcontroller determining whether at least one of the first, second, and third voltage values is less than a desired minimum cell voltage value;

the microcontroller replacing the at least one of the first, second, and third voltage values that is less than the desired minimum cell voltage value with a desired cell voltage value, the desired cell voltage value being greater than the desired minimum cell voltage value;

the microcontroller summing the first, second, and third voltage values to obtain a battery module low voltage sum value; and

the microcontroller generating a first control signal to induce a contactor to transition to an open operational position to electrically decouple the battery module from an electrical load, if a difference between the battery module low voltage sum value and the battery module voltage value is greater than or equal to the battery module voltage out-of-range low error value indicating the voltage out-of-range low condition, the battery module voltage out-of-range low error value is equal to a square root of a first sum of squares value therein, the first sum of squares value is equal to a sum of first, second, and third battery cell weighted voltage measurement error square values and a battery module voltage measurement error square value.

18. The system of claim 16, wherein the microcontroller generating a first message indicating the voltage out-of-range low condition of the battery module if the difference between the battery module low voltage sum value and the battery module voltage value is greater than or equal to the battery module voltage out-of-range low error value indicating the voltage out-of-range low condition.

19. The system of claim 16, wherein the first battery cell weighted voltage measurement error square value is not equal to the second and third battery cell weighted voltage measurement error square values;

and the second battery cell weighted voltage measurement error square value is not equal to the first and third battery cell weighted voltage measurement error square values.

20. The system of claim 16, wherein:

the first battery cell weighted voltage measurement error square value is equal to a square of a weighted measurement error associated with the first voltage level;

the second battery cell weighted voltage measurement error square value is equal to a square of a weighted measurement error associated with the second voltage level; and

the third battery cell weighted voltage measurement error square value is equal to a square of a weighted measurement error associated with the third voltage level.

21. The system of claim 16, wherein the battery module voltage measurement error square value is equal to a square of a measurement error associated with the battery module voltage level.

22. The system of claim 16, further comprising:

a first voltage sensor being electrically coupled to the first battery cell, the first voltage sensor outputting the first signal indicating the first voltage level being output by the first battery cell;

a second voltage sensor being electrically coupled to the second battery cell, the second voltage sensor outputting the second signal indicating the second voltage level being output by the second battery cell;

a third voltage sensor being electrically coupled to the third battery cell, the third voltage sensor outputting the third signal indicating the third voltage level being output by the third battery cell;

a battery module voltage sensor being electrically coupled to the battery module, the battery module voltage sensor outputting the fourth signal indicating the battery module voltage level being output by the battery module; and

the microcontroller operably coupled to the first, second, and third voltage sensors, the battery module voltage sensor, and a memory device;

the memory device having the battery module voltage out-of-range low error value therein.