Hybrid battery control system architecture systems and methods

• US 10,411,484 B2
• Filed: 08/31/2016
• Issued: 09/10/2019
• Est. Priority Date: 11/04/2015
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: CPS Technology Holdings, LLC
• Inventors: Dulle, Ronald J., Tosch, Charles S., Ellner, Fredrick C., Gunderson, Mark D.
• Primary Examiner(s): Riyami, Abdullah A
• Assistant Examiner(s): Alhawamdeh, Nader J
• Application Number:
  US15/253,446
• Publication Number:
  US 20170125784A1
• Time in Patent Office: 1,105 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; and a battery control system. The battery control system includes a first cell control that determines first module level operational parameters related to operation of the first battery module; a second cell control that determines second module level operational parameters related to operation of the second battery module; a string control unit communicatively that determines string level operational parameters related to operation of the battery string based at least in part on the first and second module level operational parameters; and a system control unit that determines system level operational parameters related to operation of the battery system based at least in part on the string level operational parameters; and controls operation of the battery system based at least in part on the system 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, wherein the first battery module comprises a plurality of battery cells; and

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; and

the first battery module comprises a housing that houses the plurality of battery cells and the first cell control unit, wherein the first cell control unit does not include a microprocessor or an isolation barrier;

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

a first string control unit communicatively coupled to the first cell control unit and the second cell control unit, wherein the first string control unit is configured to;

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

a system control unit communicatively coupled to the first string control unit, wherein the system control unit is configured to;

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

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

2. The battery system of claim 1, wherein the first cell control unit comprises:

a first sensor communication interface configured to receive a first analog representation of a first cell group voltage from a first voltage sensor;

a first analog-to-digital converter communicatively coupled to the first sensor communication interface, wherein the first analog-to-digital converter is configured to generate a first digital representation of the first cell group voltage based at least in part on the first analog representation;

a second sensor communication interface configured to;

receive a second analog representation of a second cell group voltage from a second voltage sensor;

receive a third analog representation of a battery module voltage from a third sensor;

a second analog-to-digital converter communicatively coupled to the second sensor communication interface, wherein the second analog-to-digital converter is configured to;

generate a second digital representation of the second cell group voltage based at least in part on the second analog representation;

generate a third digital representation of the battery module voltage based at least in part on the third analog representation;

logic circuitry communicatively coupled to the first analog-to-digital converter and the second analog-to-digital converter, wherein the logic circuitry is configured to perform a logic operation, an arithmetic operation, or both based at least in part on the first digital representation, the second digital representation, the third digital representation, or any combination thereof; and

a serial communication interface configured to communicatively couple the first cell control unit to the first string control unit via a serial communication network.

3. The battery system of claim 1, wherein the first string control unit comprises:

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

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

an isolation barrier comprising a transformer and an electrically isolated communication interface, wherein the isolation barrier is configured to electrically isolate a high voltage portion of the first string control unit from a low voltage portion of the first string control unit;

processing circuitry communicatively coupled directly to the high voltage serial communication interface and communicatively coupled to the parallel communication interface, the low voltage serial communication interface, or both via the electrically isolated communication interface, wherein the processing circuitry is configured to determine the first string level operational parameters by processing received data based at least in part on programmable circuit connections; and

a processing unit communicatively coupled directly to the high voltage serial communication interface and communicatively coupled to the parallel communication interface, the low voltage serial communication interface, or both via the electrically isolated communication interface, wherein the processing unit is configured to determine the first string level operational parameters by processing the received data received based at least in on executable instructions stored in memory.

4. The battery system of claim 1, wherein the system control unit comprises:

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

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

an external communication interface configured to communicatively couple the battery system to an external communication network; and

a processing unit communicatively coupled to the parallel communication interface, the serial communication interface, and the external communication interface, wherein the processing unit determine the system level operational parameters based at least in part on executable instructions stored in memory.

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

implementing a cell control unit to be used to determine first operational parameters related to operation of a battery module by;

communicatively coupling a first analog-to-digital converter to a first sensor communication interface to enable the cell control unit to receive a first analog representation of first sensor data from a first sensor and 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 cell control unit to communicate data within the battery control system via a first serial communication network; and

implementing a string control unit to be used to control operation of a battery string comprising the battery module by;

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

forming a first isolation barrier comprising an electrically isolated communication interface between a third serial communication interface and the second serial communication interface; and

communicatively coupling the processing circuitry, the first processing unit, or both to the third serial communication interface via the electrically isolated communication interface to enable the string control unit to communicate data via a second serial communication network.

6. The method of claim 5, comprising implementing a system control unit to be used to control operation of the battery system by:

communicatively coupling a second processing unit to a fourth serial communication interface to enable the system control unit to communicate data with the string control unit via the second serial communication network;

communicatively coupling the second processing unit to a first parallel communication interface to enable the system control unit to communicate data within the battery control system via a parallel communication network; and

communicatively coupling the second processing unit to an external communication interface to enable the battery control system to centralize external communication;

wherein implementing the string control unit comprises communicatively coupling the processing circuitry, the first processing unit, or both to a second parallel communication interface via the electrically isolated communication interface to enable the string control unit to communicate data with the system control unit via the parallel communication network.

7. The method of claim 6, wherein:

implementing the string control unit comprises communicatively coupling the processing circuitry, the first processing unit, or both to a string relay communication interface to enable the string control unit to instruct a string relay to connect or disconnect the battery string from the battery system; and

implementing the system control unit comprises communicatively coupling the second processing unit to a system relay communication interface to enable the system control unit to instruct a system relay to connect or disconnect the battery system from an electrical load.

8. The method of claim 5, wherein implementing the cell control unit comprises:

electrically coupling the cell control unit to a terminal of the battery module to enable the cell control unit to receive high voltage electrical power from the battery module and to determine the first operational parameters based at least in part on the high voltage electrical power;

physically coupling the cell control unit to a housing of the battery module; and

forming the logic circuitry to enable the logic circuitry to perform the logic operation, the arithmetic operation, or both based at least in part on circuit connection in the logic circuitry.

9. The method of claim 5, wherein implementing the string control unit comprises:

forming programmable circuit connections in the processing circuitry to enable the processing circuitry to determine second operational parameters related to operation of the battery string, determine control commands, or both based at least in part on the programmable circuit connections; and

storing instructions executable by the first processing unit in memory to enable the first processing unit to determine the second operational parameters, determine the control commands, or both by executing the instructions;

wherein forming the first isolation barrier comprises forming the first isolation barrier to electrically isolate the processing circuitry and the first processing unit from the third serial communication interface.

10. The method of claim 5, wherein implementing the cell control unit comprises:

communicatively coupling a second analog-to-digital converter to a second sensor communication interface to enable the cell control unit to;

receive a second analog representation of second sensor data from a second sensor; and

generate a second digital representation of the second sensor data; and

communicatively coupling the logic circuitry to the second 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 second digital representation of the second sensor data.

11. The method of claim 5, wherein implementing the cell control unit comprises implementing the cell control unit without a microprocessor and without a second isolation barrier.

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

indicate, using the one or more processors, a first cell control unit to be electrically coupled to a first battery module in a battery system to enable the first cell control unit to receive high voltage electrical power from the first battery module and determine first operational parameters related to operation of the first battery module;

indicate, using the one or more processors, a first string control unit to be communicatively coupled to the first cell control unit via a first serial communication network to enable the first string control unit to control operation of a first battery string comprising the first battery module based at least in part on the first operational parameters;

indicate, using the one or more processors, a system control unit to be;

communicatively coupled to the first string control unit via a second serial communication network and a parallel communication network to enable the system control unit to coordinate operation of the first battery string with a second battery string in the battery system; and

electrically coupled to an external power source to enable the system control unit to receive low voltage electrical power from the external power source.

13. The computer-readable medium of claim 12, comprising instructions to:

indicate, using the one or more processors, the first string control unit to be electrically coupled to the first battery module to enable the first string control unit to receive the high voltage electrical power; and

indicate, using the one or more processors, the first string control unit to be electrically coupled to the external power source to enable the first string control unit to receive the low voltage electrical power;

wherein the first string control unit comprises an isolation barrier to electrically isolate a first portion of the first string control unit operating using the high voltage electrical power from a second portion of the first string control unit operating using the low voltage electrical power.

14. The computer-readable medium of claim 12, comprising instructions to indicate, using the one or more processors, the system control unit to be communicatively coupled to an external communication network to enable the battery control system to centralize communication with the external communication network through the system control unit.

15. A battery system comprising:

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

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

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

a first string control unit communicatively coupled to the first cell control unit and the second cell control unit, wherein the first string control unit is configured to;

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;

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

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

a second string control unit communicatively coupled to the third cell control unit, the fourth cell control unit, and the system control unit, wherein the second string control unit is configured to 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

a system control unit communicatively coupled to the first string control unit and the second string control unit, wherein the system control unit is configured to;

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

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

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

16. The battery system of claim 15, 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 battery control system comprises a chain control unit physically coupled to the first string control unit, wherein the chain control unit is configured to determine chain level operational parameters related to operation of the battery chain.

17. The battery system of claim 15, wherein the system control unit, to control operation of the battery system, is configured to:

determine whether a fault is detected in the battery system based at least in part on the first string level operational parameters, the second string level operational parameters, or both; and

instruct a system relay to electrically disconnect the battery system from an electrical load when the fault has been detected.

18. A battery system comprising:

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

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

a first string control unit communicatively coupled to the first cell control unit and the second cell control unit, wherein the first string control unit is configured to;

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

a system control unit communicatively coupled to the first string control unit, wherein the system control unit is configured to;

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

control operation of the battery system based at least in part on the system level operational parameters

wherein the first string control unit comprises;

a first portion configured to operate using electrical power in a first voltage domain received from the first battery string;

a second portion configured to operate using electrical power in a second voltage domain received from the system control unit, an external power source, or both, wherein the second voltage domain is different from the first voltage domain; and

an isolation barrier configured to electrically isolate the first portion of the first string control unit from the second portion of the first string control unit.

19. The battery system of claim 18, wherein the isolation barrier comprises:

an isolated communication interface configured to facilitate data communication between the first portion and the second portion of the first string control unit across the isolation barrier; and

a transformer configured to;

receive electrical power in the second voltage domain from the system control unit, an external power source, or both; and

generate electrical power in the first voltage domain supplied to the first portion of the first string control unit.

20. A battery system comprising:

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

the first battery module comprises a first battery cell group that includes a first plurality of battery cells and a second battery cell group that includes a second plurality of battery cells; and

the second battery module comprises a third battery cell group that includes a third plurality of battery cells and a fourth battery cell group that includes a fourth plurality of battery cell;

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 at least in part by;

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

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

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

a second cell control unit electrically coupled to the second battery module, wherein the second cell control unit is configured to determine second module level operational parameters related to operation of the second battery module at least in part by;

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

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

determining a second battery module voltage of the second battery module;

a first string control unit communicatively coupled to the first cell control unit and the second cell control unit, wherein the first string control unit is configured to;

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

a system control unit communicatively coupled to the first string control unit, wherein the system control unit is configured to;

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

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

21. The battery system of claim 20, wherein:

the first 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; and

the first string control unit, to control operation of the first battery string, is configured to;

determine whether a fault has been detected in the first battery string; and

instruct a string relay to electrically disconnect the first battery string from the battery system.