High voltage hybrid battery pack cycler

• US 20060214637A1
• Filed: 01/18/2006
• Published: 09/28/2006
• Est. Priority Date: 03/22/2005
• Status: Active Grant

• Current Assignee: Ford Motor Company
• Original Assignee: Ford Motor Company
• Inventors: Gonzales, Philip, Patel, Bijal, Lee, Josephine, Mohammed, Majed
• Granted Patent: US 7,692,401 B2
• Time in Patent Office: Days
• US Class Current: 320/128
• CPC Class Codes: B60L 53/305 Communication interfaces
• CPC Class Codes: B60L 58/13 Maintaining the SoC within a determined range
• CPC Class Codes: H02J 7/1423 with multiple batteries
• 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 90/12 Electric charging stations
• 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

An off-board battery cycler is used to condition an on-board battery system used in electric or hybrid electric vehicles. The battery cycler periodically discharges the vehicle'"'"'s high voltage traction battery to eliminate battery “memory” that can prevent the battery from being fully charged. The cycler also recharges both the high voltage battery and an on-board low voltage battery used to power the vehicle'"'"'s electrical system. High voltage AC power used in recharging the high voltage battery is switched using contactors physically isolated within the battery cycler, in order to protect operating personnel from coming onto contact with high voltage. Faults and malfunctions are recorded by the vehicle'"'"'s on-board controller

Claims

1. Apparatus for controlling the charge on a battery system for a vehicle, the battery system including a first, low voltage battery for operating electrical systems on the vehicle and a second, high voltage traction battery, comprising:

a battery cycler for charging both the low voltage battery and the high voltage battery; and

,

a controller for controlling the operation of the battery cycler.

2. The apparatus of claim 1, wherein:

the battery cycler is further operable for periodically discharging the high voltage battery, and

the controller is operable for controlling the battery cycler to achieve a preselected state of charge on the high voltage battery.

3. The apparatus of claim 1, wherein the battery cycler includes:

a constant current source for delivering constant charging current to the high voltage battery during charging of the high voltage battery, and a

a switching circuit operated by the controller for coupling the constant current source with the high voltage battery.

4. The apparatus of claim 1, wherein the battery cycler is off-board of the vehicle, and the controller is mounted on-board the vehicle.

5. The apparatus of claim 1, wherein the battery cycler includes:

a first releasable connection for connecting the battery cycler with the high voltage battery, and

a second releasable connection for connecting the battery cycler with the controller.

6. The apparatus of claim 1, wherein the battery cycler includes a manual switch operable by a user for initiating the operation of the battery cycler.

7. The apparatus of claim 1, wherein the controller senses the state of charge of the high voltage battery and delivers a signal to the battery cycler causing the cycler to recharge the high voltage battery when the state of charge falls below a preselected level.

8. The apparatus of claim 1, wherein:

the controller periodically delivers a first, discharge control signal to the battery cycler causing the battery cycler discharge the high voltage battery to at least a first preselected state of charge, and

the controller delivers a second recharge control signal to the battery cycler following discharge of the high voltage battery, the recharge control signal causing the battery cycler to recharge the high voltage battery to at least a second preselected state of charge greater than the first state of charge.

9. The apparatus of claim 1, wherein the battery cycler includes a physically isolated electrical contactor for selectively coupling the high voltage battery in a circuit supplying high voltage power to the high voltage battery.

10. A battery charge control system for vehicles, comprising:

a battery cycler for discharging and recharging a high voltage traction battery;

a first controller for controlling the operation of the battery cycler; and

a second controller for sensing faults in the operation of the battery cycler and the first controller.

11. The apparatus of claim 10, wherein:

the cycler includes an AC contactor for coupling a source of alternating current with a load formed by the traction battery, and

the first controller delivers a set of first signals to the cycler for controlling discharging and recharging of the traction battery, and a second signal to the cycler for operating the AC contactor.

12. The apparatus of claim 10, wherein the cycler includes:

a high voltage section coupled with an AC power source for supplying constant current to the traction battery,

a low voltage section connected with the first controller for recharging a low voltage battery on-board the vehicle.

13. The apparatus of claim 10, wherein:

the first and second controller are located on-board the vehicle, and

the battery cycler is located off-board the vehicle.

14. The apparatus of claim 10, wherein the cycler includes a first high voltage section for periodically discharging and recharging the traction battery, and a low voltage section for charging a low voltage battery powering accessories on the vehicle.

15. A system for controlling the state of charge of an on-board battery system for a vehicle, wherein the battery system includes a low voltage battery for operating electrical systems on the vehicle and a high voltage traction battery, comprising:

an off-board battery cycler for discharging and recharging the high voltage battery, and for recharging the low voltage battery; and

,

an on-board controller for controlling the operation of the battery cycler to achieve a preselected state of charge on each of the high and low voltage batteries.

16. The system of claim 15, wherein the battery cycler includes:

a low voltage section for recharging the low voltage battery, and,

a high voltage section for periodically discharging and recharging the high voltage battery, the high voltage section including a physically isolated switch for switching a source of high voltage AC into a circuit with a load that includes the high voltage battery.

17. The system of claim 16, wherein the battery cycler includes a first electrical connector for releasably coupling the high voltage section with a high voltage power source, and a second electrical connector for releasably coupling the battery cycler with the controller.

18. The system of claim 16, wherein the switch is controlled by the controller.

19. The system of claim 16, wherein the high voltage section includes a constant current source used to recharge the high voltage battery.

20. The system of claim 15, wherein the battery cycler includes a load bank for use in discharging the high voltage battery.