AUTONOMOUS BATTERY CONTROL AND OPTIMIZATION

• US 20160336767A1
• Filed: 07/29/2016
• Published: 11/17/2016
• Est. Priority Date: 01/07/2014
• Status: Active Grant

• Current Assignee: Alliance For Sustainable Energy LLC, Ford Global Technologies, LLC (Ford Motor Company), The Board of Regents of the University of Colorado (University of Colorado System), Utah State University
• Original Assignee: Utah State University
• Inventors: Zane, Regan A., Evzelman, Michael, Costinett, Daniel, Maksimovic, Dragan, Anderson, Richard Dyche, Smith, Kandler, Trimboli, Michael Scott, Plett, Gregory L.
• Granted Patent: US 10,277,041 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H02J 1/102 being switching converters H02J1/108, H02J1/12 take precedence
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/0016 using shunting, discharge or bypass circuits
• CPC Class Codes: H02J 7/0048 Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/005 Detection of state of health [SOH]
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02M 3/33507 with automatic control of the output voltage or current, e.g. flyback converters H02M3/33561, H02M3/33569 take precedence

Abstract

An apparatus includes a battery state module that determines a battery state of each of a plurality of battery cells forming a battery unit. A battery state includes a health of the battery cell. A battery state of a battery cell differs from a battery state of other battery cells of the battery unit. Each battery cell is connected to a shared bus through a bypass converter that provides power from the battery cell to the shared bus. A charge/discharge modification module determines, based on battery state, an amount to vary a charging characteristic for each battery cell compared to a reference charging characteristic. Each charging characteristic varies as a function of a reference state. A charge/discharge module adjusts charging/discharging of a battery cell of the battery unit based on the charging characteristic of the battery cell.

Claims

1. An apparatus comprising:

a battery state module that determines a battery state of each battery cell of a plurality of battery cells forming a battery unit, a battery state of a battery cell comprising a health of the battery cell, wherein a battery state of at least one battery cell of the battery unit differs from a battery state of one or more other battery cells of the battery unit, each battery cell is connected to a shared bus through a bypass converter, each bypass converter providing power from the battery cell to the shared bus;

a charge/discharge modification module that determines, based on the determined battery state of each battery cell of the battery unit, an amount to vary a charging characteristic for each battery cell of the battery unit with respect to a reference charging characteristic, wherein the charging characteristic for each battery cell varies as a function of a reference state; and

a charge/discharge module that adjusts charging and discharging of a battery cell of the battery unit based on the charging characteristic of the battery cell.

2. The apparatus of claim 1, wherein the reference state comprises one of voltage of the shared bus, a reference state-of-charge, a reference cell voltage, a reference cell open circuit voltage, a reference cell history, and a reference signal from an equation calculating one or more parameters of the reference state.

3. The apparatus of claim 1, wherein each charging characteristic comprises a maximum target state-of-charge correlated to a maximum value of the reference state.

4. The apparatus of claim 3, wherein the reference charging characteristic comprises a maximum target state-of-charge of a healthiest battery cell of the battery unit correlated to the maximum value of the reference state, wherein the maximum target state-of-charge of the healthiest battery cell is higher than the maximum target state-of-charge of the battery cells of the battery unit other than the healthiest battery cell.

5. The apparatus of claim 4, wherein the maximum target state-of-charge of a battery cell is proportionally related to the maximum target state-of-charge of the healthiest battery cell based on battery state.

6. The apparatus of claim 1, wherein the reference charging characteristic comprises a charging characteristic of an average battery cell, wherein each charging characteristic comprises a maximum target state-of-charge correlated to a maximum value of the reference state, wherein the maximum target state-of-charge of each battery cell is related to the maximum target state-of-charge of the average battery cell based on battery state compared to the battery state of the average battery cell.

7. The apparatus of claim 6, wherein the charging characteristic of the average battery cell comprises one of:

an average battery state based on the battery states of each battery cell of the battery unit; and

a predetermined reference charging characteristic.

8. The apparatus of claim 1, wherein the charge/discharge modification module populates an objective map for each battery cell of the battery unit, the objective map of a battery cell comprising a target state-of-charge for each value of the reference state between at least a maximum value of the reference state and a minimum value of the reference state.

9. The apparatus of claim 8, wherein each objective map comprises a same target state-of-charge for a transition value of the reference state, the transition value of the reference state comprising a value of the reference state between the minimum value of the reference state and the maximum value of the reference state.

10. The apparatus of claim 9, further comprising a life control module that determines a maximum target state-of-charge for each battery cell based on the battery state of each battery cell compared to the reference charging characteristic and populates the objective map of each battery cell of the battery unit to have the same target state-of-charge at the transition voltage as the reference charging characteristic and to diverge in target state-of-charge from the reference charging characteristic as the reference state approaches the maximum value of the reference state.

11. The apparatus of claim 10, wherein the objective map for each battery cell of the battery unit diverges linearly from the same target state-of-charge at the transition value of the reference state to the maximum target state-of-charge of each battery cell of the battery unit.

12. The apparatus of claim 9, further comprising a power optimized balancing module that determines values for the objective map for a battery cell of the battery unit based on an internal resistance of the battery cell, wherein the target state-of-charge for a particular reference state below the transition value of the reference state is correlated to a battery cell voltage at or above a minimum battery cell voltage plus a voltage drop across the internal resistance of the battery cell at a maximum battery cell current.

13. The apparatus of claim 12, wherein the power optimized balancing mode module determines a minimum target state-of-charge corresponding to the minimum value of the reference state based on the internal resistance of the battery cell, wherein the minimum target state-of-charge of the battery cell is determined to maintain the battery cell voltage at the minimum battery cell voltage, while the reference state is at the minimum value of the reference state, accounting for voltage drop across the internal resistance while current for the battery cell is at a maximum cell current, wherein the power optimized balancing mode module populates the objective map of the battery cell to transition linearly between the minimum target state-of-charge and the same target state-of-charge at the transition value of the reference state.

14. The apparatus of claim 1, wherein the charge/discharge modification module determines the amount to vary the charging characteristic of a battery cell of the battery unit based on a current age of the battery cell and a target end-of-life age of a reference battery cell associated with the reference charging characteristic and a difference between a capacity of the battery cell and the reference battery cell at the current age of the battery cell and the reference battery cell.

15. The apparatus of claim 14, wherein the charge/discharge modification module adjusts a maximum target state-of-charge of the battery cell to minimize a projected difference between the capacity of the battery cell and the capacity of the reference battery cell at the target end-of-life age of the reference battery cell.

16. The apparatus of claim 1, further comprising a direct current (“

DC”

) to DC bypass converter connected between each battery cell of the battery unit and the shared bus, wherein the charge/discharge module of a battery cell of the battery unit controls the bypass converter for the battery cell to adjust charging and discharging the battery cell based on the charging characteristic of the battery cell.

17. The apparatus of claim 16, wherein the bypass converter comprises at least one dual active bridge converter stage.

18. The apparatus of claim 16, wherein each bypass converter is controlled by a separate charge/discharge module and autonomously controls charging and discharging of the connected battery cell independent of other bypass converters and associated charge/discharge modules of other battery cells of the battery unit, wherein each charge/discharge module adjusts charging and discharging based on the charging characteristic for the associated battery cell as determined by the charge/discharge modification module.

19. The apparatus of claim 18, wherein each charge/discharge module further comprises a droop controller that provides a control characteristic for each bypass converter for control of output voltage of each bypass converter, wherein the control characteristic comprises a ratio of output voltage of the bypass converter to output current of the bypass converter, the ratio comprising a value wherein output voltage of the bypass converter decreases as output current of the bypass converter decreases and the bypass converters connected to the shared bus each contribute current to the shared bus based on the charging characteristic of the respective bypass converters while output voltage of each bypass converter remains within a voltage regulation range.

20. The apparatus of claim 1, wherein the battery state module determines the battery state of a battery cell based on a battery model and input from one or more battery sensors, the battery model describes properties of the battery cells of the battery unit comprising one or more of chemical properties, electrical properties, thermal properties, and physical properties, the one or more battery sensors comprising one or more of a temperature sensor, an optical sensor, a voltage sensor, a current sensor, a pH sensor, a strain sensor, a pressure sensor, and a gas composition sensor.

21. The apparatus of claim 1, wherein at least a portion of the battery cells of the battery unit are connected in series and form a high voltage bus, the high voltage bus connected to one or more high voltage loads of an electric vehicle and wherein the shared bus feeds one or more of a battery and an auxiliary load at a voltage lower than a voltage of the high voltage bus.

22. A method comprising:

determining a battery state of each battery cell of a plurality of battery cells forming a battery unit, a battery state of a battery cell comprising a health of the battery cell, wherein a battery state of at least one battery cell of the battery unit differs from a battery state of one or more other battery cells of the battery unit, each battery cell is connected to a shared bus through a bypass converter, each bypass converter providing power from the battery cell to the shared bus;

determining, based on the determined battery state of each battery cell of the battery unit, an amount to vary a charging characteristic for each battery cell of the battery unit with respect to a reference charging characteristic, wherein the charging characteristic for each battery cell varies as a function of a reference state; and

adjusting charging and discharging of a battery cell of the battery unit based on the charging characteristic of the battery cell.

23. The method of claim 22, wherein the reference state comprises one of voltage of the shared bus, a reference state-of-charge, a reference cell voltage, a reference cell open circuit voltage, a reference cell history, and a reference signal from an equation calculating one or more parameters of the reference state.

24. The method of claim 22, wherein each charging characteristic comprises a maximum target state-of-charge correlated to a maximum value of the reference state, the reference charging characteristic comprising a maximum target state-of-charge of a healthiest battery cell of the battery unit correlated to the maximum value of the reference state, wherein the maximum target state-of-charge of the healthiest battery cell is higher than the maximum target state-of-charge of the battery cells of the battery unit other than the healthiest battery cell.

25. The method of claim 22, further comprising populating an objective map for each battery cell of the battery unit, the objective map of a battery cell comprising a target state-of-charge for each value of the reference state between at least a maximum value of the reference state and a minimum value of the reference state.

26. The method of claim 25, further comprising determining a maximum target state-of-charge for each battery cell based on the battery state of each battery cell compared to the reference charging characteristic and populating the objective map of each battery cell of the battery unit to have the same target state-of-charge at a transition value of the reference state as the reference charging characteristic and to diverge in target state-of-charge from the reference charging characteristic as the reference state approaches the maximum value of the reference state, wherein the objective map for each battery cell of the battery unit diverges linearly from the same target state-of-charge at the transition value of the reference state to the maximum target state-of-charge of each battery cell of the battery unit.

27. The method of claim 25, further comprising determining values for the objective map for a battery cell of the battery unit based on an internal resistance of the battery cell, wherein the target state-of-charge for a particular value of the reference state below a transition value of the reference state is determined to be at or above a minimum battery cell voltage plus a voltage drop across the internal resistance of the battery cell at a maximum discharge battery cell current.

28. The method of claim 27, further comprising determining a minimum target state-of-charge corresponding to the minimum value of the reference state based on the internal resistance of the battery cell, wherein the minimum target state-of-charge of the battery cell is determined to maintain the battery cell voltage at the minimum battery cell voltage, while the reference state is at the minimum value of the reference state, accounting for voltage drop across the internal resistance while current for the battery cell is at a maximum cell current, and populating the objective map of the battery cell to transition linearly between the minimum target state-of-charge and the same target state-of-charge at the transition value of the reference state.

29. The method of claim 22, wherein determining the amount to vary the charging characteristic of a battery cell of the battery unit is based on a current age of the battery cell and a target end-of-life age of a reference battery cell associated with the reference charging characteristic and a difference between a capacity of the battery cell and the reference battery cell at the current age of the battery cell and the reference battery cell.

30. The method of claim 29, further comprising adjusting a maximum target state-of-charge of the battery cell to minimize a projected difference between the capacity of the battery cell and the capacity of the reference battery cell at the target end-of-life age of the reference battery cell.

31. A system comprising:

a plurality of direct current (“

DC”

) to DC bypass converters, each bypass converter connected to a battery cell of a plurality of battery cells forming a battery unit, and to a shared bus, the battery unit providing power to a load, each bypass converter providing power from the battery cell to a shared bus;

a battery state module that determines a battery state of each battery cell of the battery unit, a battery state of a battery cell comprising a health of the battery cell, wherein a battery state of at least one battery cell of the battery unit differs from a battery state of one or more other battery cells of the battery unit;

a charge/discharge modification module that determines, based on the determined battery state of each battery cell of the battery unit, an amount to vary a charging characteristic for each battery cell of the battery unit with respect to a reference charging characteristic, wherein the charging characteristic for each battery cell varies as a function of a reference state; and

a charge/discharge module that adjusts charging and discharging of a battery cell of the battery unit based on the charging characteristic of the battery cell.

32. The system of claim 31, further comprising one or more of the battery unit and the shared bus, wherein the shared bus provides power to one or more of a shared bus battery and an auxiliary load.