Electric vehicle battery test

• US 10,421,367 B2
• Filed: 10/27/2016
• Issued: 09/24/2019
• Est. Priority Date: 10/30/2015
• Status: Active Grant

• Current Assignee: Faraday & Future Inc.
• Original Assignee: Faraday & Future Inc.
• Inventors: Alser, John, Chidester, Douglas D., Paryani, Anil, Weicker, Phillip John
• Primary Examiner(s): Phan, Hau V
• Application Number:
  US15/336,034
• Publication Number:
  US 20170120771A1
• Time in Patent Office: 1,062 Days
• Field of Search: 180 658
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 7/0007 the motor being electric
• 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: G01R 31/006 on road vehicles, e.g. automobiles or trucks testing of ignition installations peculiar to internal combustion engines F02P17/00
• CPC Class Codes: G01R 31/007 using microprocessors or computers
• CPC Class Codes: G01R 31/3644 Constructional arrangements
• 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: G01R 31/52 Testing for short-circuits, leakage current or ground faults
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

An adaptive and adjustable isolation fault testing of a multi-string battery of an electric vehicle is disclosed. The isolation fault testing can be performed in an adjustable or predetermined loop having dedicated time windows for respective battery strings in compliance with the system requirements, specification, and regulatory regime.

Claims

1. An electric vehicle comprising:

a motor coupled to one or more wheels of the electric vehicle;

an inverter coupled to the motor;

a first power bus coupled to the inverter; and

a first battery string having an output that is coupled to the first power bus through a first switch,

a second battery string different from the first battery string having an output that is coupled to the first power bus through a second switch different from the first switch;

for each of the first and second battery string;

a first test load with a known impedance connected to a positive node of the respective battery string and a second test load with a known impedance connected to a negative node of the respective battery string; and

a battery management circuit coupled to at least the first switch and the second switch, the battery management circuit configured to selectively and independently control the open or closed state of the first switch and the second switch, the battery management circuit further configured to perform isolation fault testing by;

performing testing steps including;

during a first predetermined time window of a timeframe, determining an isolation status of the first battery string, during a second predetermined time window of the timeframe, determining an isolation status of the second battery string, calculating a new time window value based on the isolation status of the first battery string, and setting the first predetermined time window to the new time window value; and

repeating the testing steps;

wherein the isolation status of each of the first and second battery strings is determined by;

comparing a first voltage measurement across the first test load between the positive node and a chassis ground of the electric vehicle with a first expected voltage based on the impedance of the first test load; and

comparing a second voltage measurement across the second test load between the negative node and the chassis ground of the electric vehicle with a second expected voltage based on the impedance of the second test load.

2. The electric vehicle of claim 1, wherein the battery management circuit is configured to perform isolation fault testing while the inverter is drawing current from the first power bus.

3. The electric vehicle of claim 2, wherein the battery management circuit is configured to determine an isolation status of a battery pack including the first battery string and the second battery string, the isolation status of the battery pack being determined based at least in part on the isolation status of the first battery string and the isolation status of the second battery string.

4. The electric vehicle of claim 1, further comprising at least one test current path coupled to each battery string and switchably connected to a chassis of the electric vehicle, each test current path comprising a test load.

5. The electric vehicle of claim 4, further comprising current detection circuitry coupled to the battery management circuit and configured to measure a current flowing through a test current path, wherein the current detection circuitry is configured to send measured current information to the battery management circuit.

6. The electric vehicle of claim 5, wherein the isolation fault testing comprises comparing the measured current information to at least one of predetermined information associated with a normal condition and predetermined information associated with a fault condition.

7. The electric vehicle of claim 1, wherein the battery management circuit is configured to perform the isolation fault testing for each battery string during one of a plurality of predetermined dedicated testing time windows including the first and second predetermined time windows.

8. The electric vehicle of claim 7, wherein the battery management circuit is further configured to implement an intentional delay time window between consecutive testing time windows.

9. A method of testing a plurality of battery strings in an electric vehicle comprising:

performing a battery test, the battery test steps comprising;

disconnecting a first battery string from a power bus of the electric vehicle;

during a first predetermined time window within a timeframe, determining an isolation status of the first battery string by performing an isolation fault test on the first battery string;

reconnecting the first battery string to the power bus;

while the first battery string remains connected to the power bus, disconnecting a second battery string from the power bus of the electric vehicle;

during a second predetermined time window within the timeframe, determining an isolation status of the second battery string by performing an isolation fault test on the second battery string;

calculating a new time window value different from the first predetermined time window based on the isolation status of the first battery string;

setting the first predetermined time window to the new time window value; and

repeating the steps of the battery test;

wherein performing the isolation fault test on each tested battery string comprises;

comparing a first voltage measurement across a first test load between a positive node of the tested battery string and a chassis ground of the electric vehicle with a first expected voltage based on a known impedance of the first test load;

comparing a second voltage measurement across a second test load between a negative node of the tested battery string and the chassis ground of the electric vehicle with a second expected voltage based on a known impedance of the second test load.

10. The method of claim 9, wherein the isolation fault tests are performed during operation of the electric vehicle.

11. The method of claim 9, further comprising determining an isolation status of a battery pack including the first battery string and the second battery string, the isolation status of the battery pack being determined based at least in part on the isolation status of the first battery string and the isolation status of the second battery string.

12. The method of claim 9, wherein at least one additional battery string is connected to the power bus while the first battery string is disconnected.

13. The method of claim 9, wherein the isolation fault test is performed on each tested battery string during one of a plurality of a-predetermined dedicated testing time windows including the first and second predetermined time windows.

14. The method of claim 13, wherein consecutive testing time windows are separated by an intentional delay time window.

15. The method of claim 9, wherein, upon repeating the steps of the battery test, the second predetermined time window is not changed.

16. The method of claim 9, wherein the battery test steps further comprise:

calculating a second new time window value based on the new time window value, and setting the second predetermined time window to the second new time window value.

17. The method of claim 16, wherein, upon repeating the battery test steps, the order of determining an isolation status of the first battery string and determining the isolation status of the second battery string are reversed.