Battery energy monitoring circuits

• US 5,670,861 A
• Filed: 01/17/1995
• Issued: 09/23/1997
• Est. Priority Date: 01/17/1995
• Status: Expired due to Term

• Current Assignee: Minit Charger, LLC
• Original Assignee: Norvik Traction, Inc.
• Inventors: Nor, Jiri K.
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): SHIN, KYUNG E
• Application Number:
  US08/372,936
• Time in Patent Office: 980 Days
• Field of Search: 320/15, 320/17-18, 320/21, 320/5-6, 320/48, 320/47, 320/49, 320/54-55, 320/29, 320/31, 320/27-28
• US Class Current: 320/118
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 2250/16 by display
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 3/0092 with use of redundant elements for safety purposes
• CPC Class Codes: B60L 50/20 using propulsion power generated by humans or animals
• CPC Class Codes: B60L 53/11 DC charging controlled by the charging station, e.g. mode 4
• CPC Class Codes: B60L 58/13 Maintaining the SoC within a determined range
• CPC Class Codes: B60L 58/14 Preventing excessive discharging
• CPC Class Codes: B60L 58/15 Preventing overcharging
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/22 Balancing the charge of battery modules
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: G01R 31/3648 comprising digital calculation means, e.g. for performing an algorithm
• CPC Class Codes: G01R 31/3842 combining voltage and current 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: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 2310/48 for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0016 : using shunting, discharge or bypass circuits
• CPC Class Codes: H02J 7/0031 : using battery or load disconnect circuits H02J9/002 takes precedence
• CPC Class Codes: H02J 7/0048 : Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/02 : for charging batteries from ac mains by converters
• 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

A long chain battery, particularly for an electric vehicle, comprises a plurality of series connected cells or battery modules. To control the operation of the electrical functions, including discharge while the vehicle is being driven, charging when it is at a charging station, or regenerative charging during braking, a main control module and a plurality of battery monitoring modules are provided. The electric motor and a traction controller therefor are connected in series across the long chain battery, and other vehicle electrical loads are in parallel with the motor and controller. Each battery monitoring module will monitor a number of batteries, and the current carrying wire between them, so that incipient problems may be detected before failure or significant damage occurs. A serial communications bus is provided between the main control module and the battery monitoring modules, and data transmitted over that bus is generally digitally encoded. Sensitive analog circuitry in the battery monitoring modules is located in proximity to the battery modules with which it is associated, and is galvanically isolated from the digital communication circuitry and the data communications bus transmitting the data to the main control module. Any switching or other controllers in the battery are galvanically isolated from the battery monitoring modules and the main control module. Means are provided to isolate specific cells or battery modules, as required; other means are provided to ensure that important voltage and/or current samplings are indicative of equilibrium of the electrical charge or discharge reactions, so that erroneous readings taken during fast acceleration or braking, or other circumstances except essentially steady state conditions, may be discarded. Other means are provided whereby the driver of an electric vehicle receives warnings as the available energy still within the battery depletes below specified levels; and further means are provided to ensure that rate of discharge or regenerative charging of the battery do not exceed predetermined limits.

Claims

1. A method of taking the resistance free voltage reading of a long chain battery during charging from a battery charger or discharge thereof, wherein said long chain battery is installed in an electric vehicle together with a monitoring and control apparatus therefor;

wherein said long chain battery comprises a plurality of series connected cells or battery modules;

wherein said electric vehicle has installed therein a main control module, at least one battery monitoring module which is associated with a respective plurality of cells or battery modules, a current sensor means in series with said long chain battery, a vehicle communication bus, a drive controller, an electric motor and a traction controller therefor in series across said battery, other vehicle electrical loads in parallel with said series connected electric motor and traction controller, current control means and current flow interruption means within said main control module, a serial communications bus, and voltage reading means for receiving and storing voltage information for each cell or battery module from each of said battery monitoring modules;

wherein said method comprises following any one of the following steps;

I;

providing a parallel connection of a high current capacity switch and a rearward facing diode in series with said electric motor and traction controllers;

a free wheeling diode in parallel with said series connected electric motor and traction controller, and an energy storage filter comprising an inductor in series with said switch or a capacitor in parallel with said switch, or both;

periodically interrupting the control of current through said switch by opening said switch for a diagnostic period of time less than the time constant of said energy storage filter so as to continue to feed electrical energy to said electric motor; and

taking a voltage reading for each cell or battery module while said switch is open;

II;

providing means for controlling said traction controller;

reading the instantaneous current flowing through said long chain battery;

controlling said traction controller whereby said electric motor may be controlled to draw a current which is significantly different from the current just previously flowing to said electric motor for a diagnostic period for from about 3 to about 10 ms, taking a current reading of current through said long chain battery during said diagnostic period;

comparing the current reading taken just prior to said diagnostic period with the current reading taken during said diagnostic period, and mathematically extrapolating the resistance free voltage from said current readings, due to the linear relationship of direct current voltage, current, and resistance under Ohm'"'"'s law;

III;

providing means for controlling said traction controller;

reading the instantaneous current flowing through said long chain battery;

controlling said traction controller whereby said electric motor may be reversed for a brief diagnostic period to a level which is equal to the current being drawn by said other electrical loads, whereby the current flowing through said battery is reduced to zero; and

determining the resistance free voltage of said long chain battery while the current flow therethrough is zero;

IV;

providing a parallel connection of a high current capacity switch and a rearward facing diode in series with said other vehicle electrical loads but beyond said series connected electric motor and traction controller;

reading the instantaneous current flowing through said long chain battery;

periodically interrupting the control of current through said switch by opening said switch for a diagnostic period of time;

taking a current reading of current through said long chain battery while said switch is open; and

comparing the current reading taken just prior to opening said switch with the current reading taken during said diagnostic period, and mathematically extrapolating the resistance free voltage from said current readings, due to the linear relationship of direct current voltage, current, and resistance under Ohm'"'"'s law;

or

V;

providing a series connection of a further load resistor and a high current capacity switch, in parallel with said series connected electric motor and traction controller, wherein said switch is galvanically isolated from said main control module;

reading the instantaneous current flowing through said long chain battery, periodically closing said switch for a diagnostic period of time;

taking a current reading of current through said long chain battery while said switch is closed; and

comparing the current reading taken just prior to closing said switch with the current reading taken during said diagnostic period, and mathematically extrapolating the resistance free voltage from said current readings, due to the linear relationship of direct current voltage, current, and resistance under Ohm'"'"'s law.

2. The method of claim 1, wherein for any voltage or current readings taken, three readings are taken at identical time intervals, where the first reading is taken just prior to the initiation of the diagnostic period, the second reading is taken after time interval "t" during said diagnostic period and just before the end thereof, and the third reading is taken after a further time interval "t" which occurs after said diagnostic period;

calculating the slope characterizing the three readings by the following determination;

##EQU5## and if the calculated slope exceeds a predetermined value, discarding the readings as being not indicative of equilibrium of the electrical charge or discharge reaction of said long chain bakery.

3. The method of claim 2, wherein each of said three readings is determined by taking several discrete readings taken within short time intervals of between 5% to 20% of interval "t", and then digitally filtering and averaging said discrete readings.

4. The method of claim 1, wherein for any voltage or current readings taken, said diagnostic pulses occur from 5 to 30 seconds apart, a series of 2 to 10 readings are taken in the 2 to 4 seconds just preceding the initiation of each diagnostic pulse, and then said series of readings are compared one to another;

and

if each of said series of readings falls within a predetermined range, or if each succeeding reading is either higher or lower than the preceding reading within a predetermined range, then said readings are accepted as being indicative of equilibrium of the electrical charge or discharge reaction of said long chain battery.