SYSTEMS, METHODS, AND DEVICES FOR PRE-CHARGE CONTROL OF A BATTERY MODULE

• US 20150069829A1
• Filed: 03/31/2014
• Published: 03/12/2015
• Est. Priority Date: 09/06/2013
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Thieme, Bryan L., Dulle, Ronald J., Gunderson, Mark D.
• Granted Patent: US 10,581,056 B2
• Time in Patent Office: Days
• US Class Current: 307/9.1
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 1/02 to electric heating circuits
• CPC Class Codes: B60L 1/14 to electric lighting circuits
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2240/34 Cabin temperature
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 2260/26 Transition between different drive modes
• CPC Class Codes: B60L 2270/20 Inrush current reduction, i.e. avoiding high currents when connecting the battery
• 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 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• 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 58/15 : Preventing overcharging
• 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: B60L 58/26 : by cooling
• CPC Class Codes: B60R 16/03 : for supply of electrical power to vehicle subsystems or for circuit arrangements for charging batteries H02J7/00
• 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: G01R 31/3835 : involving only voltage measurements
• CPC Class Codes: G01R 31/385 : Arrangements for measuring battery or accumulator variables for monitoring G01R31/382
• CPC Class Codes: G01R 31/52 : Testing for short-circuits, leakage current or ground faults
• CPC Class Codes: H01H 47/325 : by switching regulator
• CPC Class Codes: H01M 10/0413 : Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• CPC Class Codes: H01M 10/058 : Construction or manufacture
• 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 10/4257 : Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H01M 10/482 : for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/486 : for measuring temperature
• CPC Class Codes: H01M 10/6551 : Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• 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 2010/4278 : Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
• CPC Class Codes: H01M 2200/103 : Fuse
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 2250/20 : Fuel cells in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 4/661 : Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/665 : Composites
• CPC Class Codes: H01M 50/20 : Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders structural combination of accumulators with charging apparatus H01M10/46
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/264 : for cells or batteries, e.g. straps, tie rods or peripheral frames
• CPC Class Codes: H01M 50/271 : Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/287 : Fixing of circuit boards to lids or covers
• CPC Class Codes: H01M 50/291 : characterised by their shape
• CPC Class Codes: H01M 50/30 : Arrangements for facilitating escape of gases
• CPC Class Codes: H01M 50/308 : Detachable arrangements, e.g. detachable vent plugs or plug systems
• CPC Class Codes: H01M 50/342 : Non-re-sealable arrangements
• CPC Class Codes: H01M 50/35 : Gas exhaust passages comprising elongated, tortuous or labyrinth-shaped exhaust passages
• CPC Class Codes: H01M 50/358 : External gas exhaust passages located on the battery cover or case
• CPC Class Codes: H01M 50/367 : Internal gas exhaust passages forming part of the battery cover or case; Double cover vent systems
• CPC Class Codes: H01M 50/50 : Current conducting connections for cells or batteries
• CPC Class Codes: H01M 50/502 : Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
• CPC Class Codes: H01M 50/507 : comprising an arrangement of two or more busbars within a container structure, e.g. busbar modules
• CPC Class Codes: H01M 50/528 : Fixed electrical connections, i.e. not intended for disconnection
• CPC Class Codes: H01M 50/529 : Intercell connections through partitions, e.g. in a battery casing
• CPC Class Codes: H01M 50/543 : Terminals
• CPC Class Codes: H01M 50/569 : Constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals battery terminal connectors with integrated measuring arrangements G01R31/364
• CPC Class Codes: H01M 50/571 : Methods or arrangements for affording protection against corrosion; Selection of materials therefor
• CPC Class Codes: H01M 50/572 : Means for preventing undesired use or discharge
• CPC Class Codes: H01M 50/583 : in response to current, e.g. fuses
• CPC Class Codes: H01M 50/597 : Protection against reversal of polarity
• CPC Class Codes: H01R 12/716 : Coupling device provided on the PCB
• CPC Class Codes: H02H 7/18 : for batteries; for accumulators
• CPC Class Codes: H05K 1/0218 : by printed shielding conductors, ground planes or power plane H05K1/0236 takes precedence
• CPC Class Codes: H05K 1/0262 : Arrangements for regulating voltages or for using plural voltages
• CPC Class Codes: H05K 1/0263 : High current adaptations, e.g. printed high current conductors or using auxiliary non-printed means; Fine and coarse circuit patterns on one circuit board H05K1/0293 takes precedence
• CPC Class Codes: H05K 1/0298 : Multilayer circuits
• CPC Class Codes: H05K 1/18 : Printed circuits structurally associated with non-printed electric components H05K1/0201, H05K1/023, H05K1/0243, and H05K1/16 take precedence
• CPC Class Codes: H05K 2201/0715 : provided by an outer layer of PCB
• CPC Class Codes: H05K 2201/09327 : Special sequence of power, ground and signal layers in multilayer PCB
• CPC Class Codes: H05K 2201/10492 : Electrically connected to another device
• CPC Class Codes: H05K 2201/1053 : Mounted components directly electrically connected to each other, i.e. not via the PCB
• CPC Class Codes: H05K 2201/10545 : Related components mounted on both sides of the PCB
• CPC Class Codes: H05K 3/32 : electrically connecting electric components or wires to printed circuits
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• 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: Y10T 29/49108 : Electric battery cell making
• CPC Class Codes: Y10T 29/4911 : including sealing
• CPC Class Codes: Y10T 29/49114 : including adhesively bonding

Abstract

The present subject matter relates to a battery module for use in a vehicle. The battery module may include a housing, a plurality of battery cells disposed within the housing, and solid state pre-charge control circuitry that pre-charges a direct current (DC) bus that may be coupled between the battery module and an electronic component of the vehicle. Furthermore, the solid state pre-charge control circuitry may include solid state electronic components as well as passive electronic components.

Claims

1. A battery module for use in a vehicle, comprising:

a housing;

a plurality of battery cells disposed in the housing;

solid state pre-charge control circuitry configured to pre-charge a direct current (DC) bus coupled between the battery module and an electronic component of the vehicle, the solid state pre-charge control circuitry comprising solid state electronic components and passive electronic components.

2. The battery module of claim 1, comprising a printed circuit board (PCB) disposed in the housing, wherein the solid state pre-charge control circuitry is mounted on the PCB.

3. The battery module of claim 2, wherein the PCB comprises an override system configured to provide an override signal to the solid state pre-charge control circuitry, and wherein the override signal disables the solid state pre-charge control circuitry.

4. The battery module of claim 1, wherein the solid state pre-charge control circuitry comprises:

a transistor configured to receive an input signal indicative of a pre-charge initiation request, wherein the transistor is configured to activate to provide a low resistance path between the plurality of battery cells and a ground upon receiving the pre-charge initiation request;

a power transistor coupled between the plurality of battery cells and the DC bus and configured to create a path from the plurality of battery cells to the DC bus when the transistor is activated; and

a voltage divider configured to receive an output of the power transistor and to output a pre-charge voltage to the DC bus to pre-charge the DC bus.

5. The battery module of claim 4, wherein the power transistor comprises a power metal-oxide-semiconductor field effect transistor (MOSFET).

6. The battery module of claim 4, wherein the voltage divider comprises a first set of resistors and a second set of resistors, and wherein a first resistance of the first set of resistors is substantially smaller than a second resistance of the second set of resistors.

7. The battery module of claim 6, wherein the first set of resistors is disposed between the output of the power transistor and the second set of resistors, and wherein the second set of resistors is disposed between the first set of resistors and ground.

8. The battery module of claim 1, wherein the solid state pre-charge control circuitry is configured to detect a presence of a short circuit across the DC bus while the pre-charge control circuitry pre-charges the DC bus.

9. The battery module of claim 8, wherein the solid state pre-charge control circuitry is configured to take a first voltage reading upon initially applying a voltage to pre-charge the DC bus and a second voltage reading after a predetermined amount of time has passed, and wherein substantially similar voltage levels in the first voltage reading and the second voltage reading indicate the short circuit is present.

10. The battery module of claim 9, wherein the second voltage reading occurs within approximately 30 ms of the first voltage reading.

11. The battery module of claim 1, wherein the solid state pre-charge control circuitry is configured to limit current received at the DC bus during a pre-charge.

12. The battery module of claim 1, wherein the solid state pre-charge control circuitry is configured to limit a current generated from an output of approximately 48 V from the plurality of battery cells disposed in the housing.

13. A battery module for use in a vehicle, comprising:

a housing;

a plurality of battery cells disposed in the housing;

a printed circuit board (PCB) disposed in the housing, wherein the PCB comprises solid state pre-charge control circuitry configured to pre-charge a direct current (DC) bus coupled between the battery module and an electronic component of the vehicle, wherein the pre-charge control circuitry comprises;

a transistor configured to receive an input signal indicative of a pre-charge initiation request, wherein the transistor is configured to activate to provide a low resistance path between the plurality of battery cells and a ground upon receiving the pre-charge initiation request;

a power metal-oxide-semiconductor field effect transistor (MOSFET) coupled between the plurality of battery cells and the DC bus and configured to create a path from the plurality of battery cells to the DC bus when the transistor is activated; and

a voltage divider configured to receive an output of the power MOSFET and to output a pre-charge voltage to the DC bus to pre-charge the DC bus.

14. The battery module of claim 13, wherein the pre-charge control circuitry comprises the AND gate, wherein the AND gate is configured to receive the input signal and an override signal from an override system of the battery module, and wherein the AND gate is configured to disable the pre-charge control circuitry upon receiving a disable indication from the override system of the battery module.

15. The battery module of claim 13, wherein the voltage divider comprises:

a first set of resistors coupled to the output of the power MOSFET and the DC bus; and

a second set of resistors coupled to the DC bus and the ground, wherein the second set of resistors has a resistance substantially larger than that of the first set of resistors.

16. The battery module of claim 15, wherein the first set of resistors comprises two or more individual resistors positioned separately on the PCB.

17. The battery module of claim 13, wherein the pre-charge control circuitry is configured to detect a short circuit across the DC bus by collecting a first voltage reading across the DC bus and a second voltage reading across the DC bus and providing an indication of a presence of the short circuit across the DC bus when substantially similar voltage levels of the first and second voltage readings occur.

18. The battery module of claim 13, wherein the pre-charge control circuitry is configured to collect the second voltage reading less than approximately 30 ms after the first voltage reading.

19. The battery module of claim 13, wherein the pre-charge control circuitry further comprises a diode disposed between the power MOSFET and the voltage divider, and wherein the diode is configured to prevent back-feeding of power to the pre-charge control circuitry from the DC bus.

20. A printed circuit board (PCB) for use in a vehicle battery module, comprising:

solid state pre-charge control circuitry configured to pre-charge a direct current (DC) bus coupled between the vehicle battery module and an electronic component of a vehicle in which the vehicle battery module is installed, wherein the pre-charge control circuitry comprises;

a transistor configured to receive an input signal indicative of a pre-charge initiation request, wherein the transistor is configured to activate to provide a low resistance path between the plurality of battery cells and a ground upon receiving the pre-charge initiation request;

a power metal-oxide-semiconductor field effect transistor (MOSFET) coupled between the plurality of battery cells and the DC bus and configured to create a path from the plurality of battery cells to the DC bus when the transistor is activated; and

a voltage divider configured to receive an output of the power MOSFET and to output a pre-charge voltage to the DC bus to pre-charge the DC bus.

21. A method, comprising:

receiving an input signal indicative of a pre-charge initiation request via a pre-charge control circuit disposed on a printed circuit board (PCB) of a battery module disposed in a vehicle;

applying, via the pre-charge control circuit, a voltage from a plurality of battery cells in the battery module to a direct current (DC) bus when the input signal is received;

collecting a first reading of a voltage across the DC bus;

collecting a second reading of the voltage across the DC bus at a predetermined time after collecting the first reading;

comparing the first and second readings; and

ceasing to apply the voltage from the plurality of battery cells to the DC bus when there is substantially no difference between the first and second readings.

22. The method of claim 21, wherein applying the voltage from the plurality of battery cells to the DC bus comprises:

activating a transistor of the pre-charge control circuit to provide a low resistance path between the plurality of battery cells in the battery module and a ground when the input signal is received;

creating, via a power metal-oxide-semiconductor field effect transistor (MOSFET), a path from the plurality of battery cells to the DC bus when the transistor is activated;

providing an output of the power MOSFET to a voltage divider; and

outputting a pre-charge voltage from the voltage divider to the DC bus to pre-charge the DC bus.

23. The method of claim 21, comprising receiving an indication of whether an override is enabled from an override system of the battery module disposed in the vehicle, wherein receiving the indication that the override is enabled results in discontinuing voltage application to the DC bus.

24. The method of claim 21, wherein the second voltage reading is collected within approximately 30 ms after the first voltage reading is collected.