Controlling electrical access to a lithium battery on a utility vehicle

• US 10,322,688 B2
• Filed: 12/30/2016
• Issued: 06/18/2019
• 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, Bradley, Robert Charles, Warden, Patrick Dwaine
• Primary Examiner(s): Tran, Khoi H
• Assistant Examiner(s): Peche, Jorge O
• Application Number:
  US15/395,245
• Publication Number:
  US 20180186316A1
• Time in Patent Office: 900 Days
• CPC Class Codes: B60L 1/00 Supplying electric power to auxiliary equipment of vehicles circuit arrangements for charging batteries H02J7/00
• CPC Class Codes: B60L 2240/80 Time limits
• CPC Class Codes: B60L 2250/26 by pedal actuation
• CPC Class Codes: B60L 53/00 Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
• CPC Class Codes: B60L 53/50 Charging stations characterised by energy-storage or power-generation means
• CPC Class Codes: B60L 58/10 for monitoring or controlling batteries
• CPC Class Codes: B60L 7/12 for vehicles propelled by dc motors
• CPC Class Codes: B60R 16/033 characterised by the use of electrical cells or batteries for propulsion puposes B60K1/04; supplying batteries to, or removing batteries from, vehicles B60S5/06; testing of charge state G01R31/36
• CPC Class Codes: B60W 2510/08 Electric propulsion units
• CPC Class Codes: H02J 7/0025 Sequential battery discharge in systems with a plurality of batteries
• CPC Class Codes: H02J 7/00711 with introduction of pulses during the charging process
• CPC Class Codes: H02J 7/00712 the cycle being controlled or terminated in response to electric parameters
• CPC Class Codes: H02J 9/005 using a power saving mode for copiers G03G15/5004
• CPC Class Codes: H02P 1/022 Security devices, e.g. correct phase sequencing
• CPC Class Codes: H02P 3/06 for stopping or slowing an individual dynamo-electric motor or dynamo-electric converter
• 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 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles

Abstract

A battery management system (BMS) controls lithium battery access on a utility vehicle. The BMS includes a battery interface that couples with a lithium battery, a load interface that couples with a set of loads of the utility vehicle, and control circuitry coupled with the battery interface and the load interface. The control circuitry mechanically disconnects the battery interface from the load interface in response to a sleep event. Additionally, after the battery interface is mechanically disconnected from the load interface, the control circuitry mechanically reconnects the battery interface to the load interface in response to a wakeup event. Furthermore, after the battery interface is mechanically reconnected to the load interface, the control circuitry maintains connection between the battery interface and the load interface to convey power from the lithium battery to the set of loads of the utility vehicle through the battery interface and the load interface.

Claims

1. A battery management system that controls lithium battery access on a utility vehicle, the battery management system comprising:

a lithium battery interface configured to couple to a lithium battery;

a power delivery interface configured to couple to a set of loads of the utility vehicle; and

control circuitry coupled with the lithium battery interface and the power delivery interface, the control circuitry being configured to;

mechanically disconnect the lithium battery interface from the power delivery interface in response to a sleep event,

after the lithium battery interface is mechanically disconnected from the power delivery interface, mechanically reconnect the lithium battery interface to the power delivery interface in response to a wakeup event, and

after the lithium battery interface is mechanically reconnected to the power delivery interface, maintain connection between the lithium battery interface and the power delivery interface to convey power from the lithium battery to the set of loads of the utility vehicle through the lithium battery interface and the power delivery interface;

wherein the control circuitry includes;

a contactor having source contacts configured to couple to the lithium battery interface, target contacts configured to couple to the power delivery interface, and an electromagnetic actuator, and

a wakeup circuit coupled with the electromagnetic actuator of the contactor, the wakeup circuit being configured to (i) actuate the electromagnetic actuator to a first position that connects the source contacts to the target contacts in response to the wakeup event, and (ii) release the electromagnetic actuator to a second position that disconnects the source contacts from the target contacts in response to the sleep event, the second position being different from the first position;

wherein the wakeup circuit includes a timer which the wakeup circuit is configured to start in response to the wakeup event; and

wherein the wakeup circuit is further configured to (i) output an actuation signal to the electromagnetic actuator of the contactor once the timer starts and before the timer expires and (ii) terminate output of the actuation signal to the electromagnetic actuator of the contactor in response to expiration of the timer, the electromagnetic actuator being spring biased from the first position toward the second position to separate the source contacts from the target contacts in response to the wakeup circuit terminating output of the actuation signal.

2. A battery management system as in claim 1 wherein the wakeup circuit is further configured to release the electromagnetic actuator to the second position that disconnects the source contacts from the target contacts in response to a low capacity event in which the lithium battery has discharged to a predefined low capacity level.

3. A battery management system as in claim 1 wherein the wakeup circuit is configured to couple to an ignition switch of the utility vehicle;

and

wherein the wakeup circuit is constructed and arranged to start the timer in response to receipt of a wakeup signal due to actuation of the ignition switch from an OFF position to an ON position.

4. A battery management system as in claim 3 wherein the wakeup circuit is further configured to couple to a foot pedal of the utility vehicle;

and

wherein the wakeup circuit is constructed and arranged to start the timer in response to receipt of a wakeup signal due to mechanical pressing of the foot pedal from a non-deflected position to a deflected position.

5. A battery management system as in claim 4 wherein the wakeup circuit is further configured to couple to the ignition switch and the foot pedal while the ignition switch and the foot pedal are connected in series to prevent the foot pedal from providing a wakeup signal to the wakeup circuit while the ignition switch is in the OFF position.

6. A battery management system as in claim 4 wherein the wakeup circuit is further configured to couple to a maintenance switch of the utility vehicle;

and

wherein the wakeup circuit is constructed and arranged to start the timer in response to receipt of a wakeup signal due to actuation of the maintenance switch from an OFF position to an ON position.

7. A battery management system as in claim 6 wherein the wakeup circuit is further configured to couple to the maintenance switch, the ignition switch, and the foot pedal while the maintenance switch, the ignition switch, and the foot pedal are connected in series to prevent the ignition switch and the foot pedal from providing a wakeup signal to the wakeup circuit while the maintenance switch is turned to the OFF position.

8. A battery management system as in claim 1 wherein the timer of the wakeup circuit is constructed and arranged to indicate that a sleep event has occurred when, after the timer is started, a predefined amount of time elapses without the timer being reset.

9. A battery management system as in claim 8 wherein the predefined amount of time is between 10 hours and 14 hours.

10. A battery management system as in claim 1 wherein the set of loads of the utility vehicle includes a motor controller and an electric motor which is coupled with the motor controller;

wherein the motor controller is configured to (i) receive stored power from the lithium battery and enters a powered state when the electromagnetic actuator actuates to the first position that connects the source contacts to the target contacts in response to the wakeup event, and (ii) no longer receive stored power from the lithium battery and transitions from the powered state to an unpowered state when the electromagnetic actuator releases to the second position that disconnects the source contacts from the target contacts in response to the sleep event; and

wherein the motor controller is constructed and arranged to control delivery of stored power from the lithium battery to the motor while the motor controller is in the powered state.

11. A battery management system as in claim 10 wherein the motor controller is further constructed and arranged to control delivery of regenerative power from the motor to the lithium battery while the motor controller is in the powered state.

12. A battery management system as in claim 10 wherein the control circuitry further includes a charge regulation circuit configured to control delivery of external power from an external power source to the lithium battery to recharge the lithium battery;

and

wherein the wakeup circuit is constructed and arranged to adjust operation of the charge regulation circuit in response to communication with the motor controller.

13. A battery management system as in claim 12 wherein the motor controller is further constructed and arranged to provide an external power notification message to the wakeup circuit when a user connects the motor controller to an external power source;

and

wherein the wakeup circuitry is constructed and arranged to control operation of the charge regulation circuit in response to receipt of the external power notification message provided by the motor controller.

14. A battery management system as in claim 12 wherein the wakeup circuit is further configured to deactivate the charge regulation circuit in response to detection of a full capacity event in which the lithium battery has charged to a predefined full capacity level.

15. A utility vehicle, comprising:

a utility vehicle body;

a lithium battery supported by the utility vehicle body;

a motor supported by the utility vehicle body;

a motor controller coupled with the motor; and

a battery management system configured to control lithium battery access on the utility vehicle, the battery management system including;

(i) a lithium battery interface that couples with the lithium battery, (ii) a power delivery interface that couples with the motor controller, and (iii) control circuitry coupled with the lithium battery interface and the power delivery interface, the control circuitry being constructed and arranged to;

mechanically disconnect the lithium battery interface from the power delivery interface in response to a sleep event,

after the lithium battery interface is mechanically disconnected from the power delivery interface, mechanically reconnect the lithium battery interface to the power delivery interface in response to a wakeup event, and

after the lithium battery interface is mechanically reconnected to the power delivery interface, maintain connection between the lithium battery interface and the power delivery interface to convey power from the lithium battery to the motor controller through the lithium battery interface and the power delivery interface;

wherein the control circuitry of the battery management system includes;

a contactor having source contacts configured to couple to the lithium battery interface, target contacts configured to couple to the power delivery interface, and an electromagnetic actuator, and

a wakeup circuit coupled with the electromagnetic actuator of the contactor, the wakeup circuit being configured to (i) actuate the electromagnetic actuator to a first position that connects the source contacts to the target contacts in response to the wakeup event, and (ii) release the electromagnetic actuator to a second position that disconnects the source contacts from the target contacts in response to the sleep event, the second position being different from the first position;

wherein the wakeup circuit includes a timer which the wakeup circuit is configured to start in response to the wakeup event; and

wherein the wakeup circuit is further configured to (i) output an actuation signal to the electromagnetic actuator of the contactor once the timer starts and before the timer expires and (ii) terminate output of the actuation signal to the electromagnetic actuator of the contactor in response to expiration of the timer, the electromagnetic actuator being spring biased from the first position toward the second position to separate the source contacts from the target contacts in response to the wakeup circuit terminating output of the actuation signal.

16. A utility vehicle as in claim 15 wherein the wakeup circuit is further configured to release the electromagnetic actuator to the second position that disconnects the source contacts from the target contacts in response to a low capacity event in which the lithium battery has discharged to a predefined low capacity level.

17. In a utility vehicle, a method of controlling lithium battery access, the method comprising:

mechanically disconnecting a lithium battery interface from a power delivery interface in response to a sleep event, the lithium battery interface coupling to a lithium battery supported by the utility vehicle, and the power delivery interface coupling to a set of loads of the utility vehicle,

after the lithium battery interface is mechanically disconnected from the power delivery interface, mechanically reconnecting the lithium battery interface to the power delivery interface in response to a wakeup event, and

after the lithium battery interface is mechanically reconnected to the power delivery interface, maintaining connection between the lithium battery interface and the power delivery interface to convey power from the lithium battery to the set of loads of the utility vehicle through the lithium battery interface and the power delivery interface;

wherein control circuitry of the vehicle includes;

a contactor having source contacts configured to couple to the lithium battery interface, target contacts configured to couple to the power delivery interface, and an electromagnetic actuator, and

a wakeup circuit coupled with the electromagnetic actuator of the contactor, the wakeup circuit being constructed and arranged to selectively output an actuation signal and terminate output of the actuation signal;

wherein mechanically reconnecting includes actuating the electromagnetic actuator to a first position that connects the source contacts to the target contacts in response to the wakeup event;

wherein mechanically disconnecting includes releasing the electromagnetic actuator to a second position that disconnects the source contacts from the target contacts in response to the sleep event, the second position being different from the first position;

wherein the wakeup circuit includes a timer;

wherein actuating the electromagnetic actuator includes;

starting the timer in response to the wakeup event, and

outputting the actuation signal to the electromagnetic actuator of the contactor once the timer starts and before the timer expires; and

wherein releasing the electromagnetic actuator includes;

terminating output of the actuation signal to the electromagnetic actuator of the contactor in response to expiration of the timer, the electromagnetic actuator being spring biased from the first position toward the second position to separate the source contacts from the target contacts in response to the wakeup circuit terminating output of the actuation signal.

18. A method as in claim 17 wherein the wakeup circuit is further configured to release the electromagnetic actuator to the second position that disconnects the source contacts from the target contacts in response to a low capacity event in which the lithium battery has discharged to a predefined low capacity level.

19. A computer program product having at least one non-transitory computer readable medium, the at least one non-transitory computer readable medium having stored thereon a set of instructions to control lithium battery access on a utility vehicle;

the set of instructions, when carried out by control circuitry, causing the control circuitry to perform a method of;

mechanically disconnecting a lithium battery interface from a power delivery interface in response to a sleep event, the lithium battery interface coupling to a lithium battery supported by the utility vehicle, and the power delivery interface coupling to a set of loads of the utility vehicle,

after the lithium battery interface is mechanically disconnected from the power delivery interface, mechanically reconnecting the lithium battery interface to the power delivery interface in response to a wakeup event, and

after the lithium battery interface is mechanically reconnected to the power delivery interface, maintaining connection between the lithium battery interface and the power delivery interface to convey power from the lithium battery to the set of loads of the utility vehicle through the lithium battery interface and the power delivery interface;

wherein control circuitry of the vehicle includes;

a contactor having source contacts configured to couple to the lithium battery interface, target contacts configured to couple to the power delivery interface, and an electromagnetic actuator, and

a wakeup circuit coupled with the electromagnetic actuator of the contactor, the wakeup circuit being constructed and arranged to selectively output an actuation signal and terminate output of the actuation signal;

wherein mechanically reconnecting includes actuating the electromagnetic actuator to a first position that connects the source contacts to the target contacts in response to the wakeup event;

wherein mechanically disconnecting includes releasing the electromagnetic actuator to a second position that disconnects the source contacts from the target contacts in response to the sleep event, the second position being different from the first position;

wherein the wakeup circuit includes a timer;

wherein actuating the electromagnetic actuator includes;

starting the timer in response to the wakeup event, and

outputting the actuation signal to the electromagnetic actuator of the contactor once the timer starts and before the timer expires; and

wherein releasing the electromagnetic actuator includes;

terminating output of the actuation signal to the electromagnetic actuator of the contactor in response to expiration of the timer, the electromagnetic actuator being spring biased from the first position toward the second position to separate the source contacts from the target contacts in response to the wakeup circuit terminating output of the actuation signal.

20. A computer program product as in claim 19 wherein the wakeup circuit is further configured to release the electromagnetic actuator to the second position that disconnects the source contacts from the target contacts in response to a low capacity event in which the lithium battery has discharged to a predefined low capacity level.