Systems and methods for state of charge and capacity estimation of a rechargeable battery

• US 10,300,807 B2
• Filed: 09/01/2016
• Issued: 05/28/2019
• Est. Priority Date: 02/04/2016
• Status: Active Grant

• Current Assignee: Clarios Advanced Solutions GmbH (Johnson Controls International plc)
• Original Assignee: Johnson Controls Advanced Power Solutions GmbH (Johnson Controls International plc), Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Jin, Zhihong H., Kuper, Christian, Wyatt, Perry M.
• Primary Examiner(s): Hoque, Farhana A
• Application Number:
  US15/254,645
• Publication Number:
  US 20170225584A1
• Time in Patent Office: 999 Days
• Field of Search: 324426, 324149, 320132
• 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 2260/44 by parameter estimation
• CPC Class Codes: B60L 3/0038 relating to sensors
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• CPC Class Codes: B60L 58/12 responding to state of charge [SoC]
• CPC Class Codes: B60L 58/16 responding to battery ageing, e.g. to the number of charging cycles or the state of health [SoH]
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: G01R 31/367 Software therefor, e.g. for battery testing using modelling or look-up tables
• CPC Class Codes: G01R 31/382 Arrangements for monitoring battery or accumulator variables, e.g. SoC
• CPC Class Codes: G01R 31/392 Determining battery ageing or deterioration, e.g. state of health
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10S 903/951 Assembly or relative location of components

Abstract

A battery system may include a battery that in operation couples to an electrical system, and a battery control module that in operation electrically couples to the battery. The battery control module may read battery data, estimate a state of charge of the battery based at least in part on the battery data, and estimate a state of charge error of the battery based on magnitudes of state of charge error sources. Additionally, the battery control module may update a state of health estimation of the battery when the state of charge error of the battery exceeds a predetermined threshold.

Claims

1. A battery system, comprising:

a battery configured to couple to an electrical system; and

a battery control module comprising a state of charge (SoC) module and a state of health (SoH) module, wherein the battery control module is configured to electrically couple to the battery, and the battery control module is configured to;

read battery data;

estimate a first state of charge of the battery based at least in part on the battery data using a first method of the SoC module;

calculate a first state of charge error of the battery associated with the estimate of the first state of charge and based on magnitudes of state of charge error sources associated with the first method;

estimate a second state of charge of the battery based at least in part on the battery data using a second method of the SoH module;

calculate a second state of charge error of the battery associated with the estimate of the second state of charge and based on magnitudes of state of charge error sources associated with the second method;

estimate a third state of charge error of the battery based on the first and the second state of charge errors; and

update a state of health estimation of the battery when the third state of charge error of the battery exceeds a predetermined threshold.

2. The battery system of claim 1, wherein the battery control module is configured to re-estimate the first state of charge of the battery based on the updated state of health estimation of the battery when the third state of charge error of the battery exceeds the predetermined threshold.

3. The battery system of claim 1, wherein the first method comprises a current integration method, an open circuit voltage measurement, or a recursive algorithm.

4. The battery system of claim 1, wherein the predetermined threshold comprises a state of charge error of 5 percent.

5. The battery system of claim 1, wherein an estimation logic module of the battery control module is configured to determine when the predetermined threshold is surpassed by the third state of charge error.

6. The battery system of claim 1, wherein when the third state of charge error exceeds the predetermined threshold, the SoH module is configured to perform an error reducing operation.

7. The battery system of claim 6, wherein the error reducing operation comprises limiting a duration between state of charge estimations.

8. The battery system of claim 6, wherein the battery control module is configured to repeatedly perform the error reducing operation until the first or the third state of charge error is below the predetermined threshold.

9. The battery system of claim 1, wherein the second state of charge error is determined based in part on an open circuit voltage correction error and the first state of charge error is determined based in part on a current integration error and a state of charge operating range.

10. The battery system of claim 1, wherein the battery data comprises battery voltage, battery current, and battery temperature.

11. The battery system of claim 1, wherein the battery control module is configured to update current values of the first state of charge, the second state of charge, or the state of health estimation, or any combination thereof, when the battery control module determines that the third state of charge error does not exceed the predetermined threshold.

12. The battery system of claim 11, wherein the battery control module is configured to update the current values of the first state of charge, the second state of charge, or the state of health, or any combination thereof, by displaying the current values of the first state of charge, the second state of charge, or the state of health of the battery, or any combination thereof on a display coupled to the electrical system.

13. A tangible, non-transitory computer readable medium of a battery control module configured to store instructions executable by a processor, wherein the instructions cause the processor to:

read battery data of a rechargeable battery;

estimate a first state of charge of the rechargeable battery based at least in part on the battery data read from the rechargeable battery;

determine a first state of charge error of the first state of charge based at least in part on magnitudes of first state of charge error sources;

estimate a second state of charge of the rechargeable battery based at least in part on the battery data read from the rechargeable battery, and a state of health of the rechargeable battery;

determine a second state of charge error of the second state of charge based at least in part on magnitudes of second state of charge error sources;

determine a third state of charge error based on the first state of charge error and the second state of charge error; and

update the state of health of the rechargeable battery when the third state of charge error exceeds a predetermined threshold.

14. The computer readable medium of claim 13, wherein the instructions cause the processor to estimate the first state of charge based on a recursive algorithm method, an open circuit voltage method, or a current integration method using the battery control module.

15. The computer readable medium of claim 13, wherein the first state of charge error sources comprise open circuit voltage correction errors and the second state of charge error sources comprise current integration errors.

16. The computer readable medium of claim 15, wherein the open circuit voltage correction errors comprise randomly distributed error sources and the current integration errors comprise time dependent state of charge error sources and depth of discharge bounded state of charge error sources.

17. The computer readable medium of claim 13, wherein the state of health is updated using a linear regression of the battery data comprising a real-time current and voltage, or the state of health is updated by monitoring an open circuit voltage of the rechargeable battery and consulting a look-up table.

18. The computer readable medium of claim 13, comprising instructions to cause the processor to control an estimation logic module of the battery control module of the rechargeable battery to determine when the predetermined threshold is surpassed by the third state of charge error.

19. The computer readable medium of claim 13, wherein the battery data comprises battery voltage, battery current, and battery temperature.

20. An energy storage system, comprising:

an electrical system of a vehicle or stationary battery;

an energy storage component configured to electrically couple to the electrical system of the vehicle or stationary battery;

at least one sensor coupled to the energy storage component and configured to collect energy storage component data from the energy storage component; and

a battery control module configured to;

estimate a first state of charge of the energy storage component based on the energy storage component data collected by the at least one sensor;

calculate a first state of charge error of the energy storage component based at least in part on magnitudes of first error sources associated with the first state of charge;

estimate a second state of charge of the energy storage component based on the energy storage component data calculated by the at least one sensor;

calculate a second state of charge error of the energy storage component based at least in part on magnitudes of second error sources associated with the second state of charge; and

update a state of health estimation of the energy storage component when a third state of charge error of the energy storage component exceeds a predetermined threshold, wherein the third state of charge error is calculated based on the first state of charge error and the second state of charge error.

21. The energy storage system of claim 20, wherein the energy storage component data comprises voltage, current, and temperature.

22. The energy storage system of claim 20, wherein the first error sources comprise open circuit voltage correction errors and the second error sources comprise current integration errors.

23. The energy storage system of claim 20, wherein the battery control module comprises an estimation logic module configured to determine when the predetermined threshold is surpassed by the third state of charge error.