Battery system and management method

• US 8,558,712 B2
• Filed: 06/03/2010
• Issued: 10/15/2013
• Est. Priority Date: 06/03/2010
• Status: Active Grant

• Current Assignee: C&C Power Incorporated
• Original Assignee: C&C Power Incorporated
• Inventors: Fechalos, William, Conrardy, N. William
• Primary Examiner(s): La, Anh V
• Application Number:
  US12/793,025
• Publication Number:
  US 20110298626A1
• Time in Patent Office: 1,230 Days
• Field of Search: 340/664, 340/636.1, 340/636.12, 340/636.13, 340/636.16, 340/636.17, 340/636.18, 340/636.19, 320/116, 320/152, 320/134, 702/63, 324/433, 324/435
• US Class Current: 340/664
• CPC Class Codes: G01R 31/382 Arrangements for monitoring battery or accumulator variables, e.g. SoC
• 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: H01M 10/06 Lead-acid accumulators semi-lead accumulators H01M10/20
• CPC Class Codes: H01M 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H02J 7/00302 Overcharge protection
• CPC Class Codes: H02J 7/00306 Overdischarge protection
• CPC Class Codes: H02J 7/00309 Overheat or overtemperature protection

Abstract

A system and method for monitoring the status of a system of battery strings is described. The system includes a current sensor for each of the battery strings, and a controller configured to compare the measured current with criteria to determine whether the battery is in a thermal runaway state. Prior to entering the thermal runaway state the battery current characteristics may indicate other less serious states. Warning messages are provided for selected events, and the battery string is disconnected from the remainder of the system when a thermal runaway state is encountered. The system may provide a local indication of status and may also interface with a communications network to provide for remote monitoring.

Claims

1. A battery system, comprising:

a current sensor, disposed so as to measure a value of current flowing in a battery string of the battery system;

a controller; and

a switch disposed in a series connection with the battery string;

wherein the battery system is operable in a discharging state, a charging state or a fully charged state, the controller is configured to compare the measured current value with a first expected current value characteristic in the charging state and a second expected current value characteristic in the fully charged state to determine whether the battery string has encountered a thermal runaway condition in one of the charging state or the fully charged states.

2. The system of claim 1, wherein the switch is actuated by a signal output from the controller.

3. The system of claim 2, wherein the switch is actuated to isolate the battery string from a battery charger, other battery strings and an external load when the thermal runaway condition is determined in either one of the charging state or the fully charged state.

4. The system of claim 3, wherein the thermal runaway condition in the charging state is determined when a time duration of the charging state of the battery string is greater than a predicted time duration of the charging state, the predicted time computed based on the characteristics of a preceding discharging state.

5. The system of claim 4, wherein the AH capacity of each of a plurality of batteries in the battery string is the same.

6. The system of claim 4, wherein the characteristics of the discharging state are a time duration of the discharge and a battery string current.

7. The system of claim 4, where the predicted time duration of the charging state is proportional to the product of a time duration of the discharging state and an average battery string discharge current during the discharging state.

8. The system of claim 3, wherein the thermal runaway condition in the charging state is determined when a sign of a slope of the measured current changes and the slope-sign-change-persists for a predetermined period of time.

9. The system of claim 8, wherein the switch is actuated when the thermal runaway condition has a duration greater than 5 minutes or the measured current is more than 30 percent greater than a minimum measured previously measured current when the battery is in the charging state.

10. The system of claim 1, wherein a estimated float current for the fully charged state is determined as a percentage of the battery ampere hour (AH) rating of a battery of the battery string.

11. The system of claim 10, wherein a thermal runaway condition is determined in the fully charged state when the measured current value, is above a first predetermined percentage of the battery AH rating in amperes and the measured current value has a increasing magnitude for at least a predetermined time after the first threshold is exceeded.

12. The system of claim 10, wherein a critical thermal runaway warning condition is determined when the measured current value in a charged state is greater than a second predetermined percentage of the battery AH rating in amperes and second current value is about twice the first predetermined percentage.

13. The system of claim 12, wherein the thermal runaway condition is determined to exist when the critical thermal runaway condition persists for more than a predetermined period of time.

14. The system of claim 13, wherein the switch is actuated to disconnect the battery string having the thermal runaway condition.

15. The system of claim 13, wherein an email message or a SNMP message is dispatched to a predetermined network address when the thermal runaway condition is determined to exist.

16. The system of claim 1, further comprising a battery charging device connectable to an external power source.

17. The system of claim 16, wherein the external power source is at least one of a motor-generator or a commercial power grid.

18. The system of claim 1, further comprising the battery string.

19. The system of claim 18, wherein the battery string is a plurality of lead-acid batteries connected in series.

20. The system of claim 1, wherein the controller communicates with a system controller using a local communications network.

21. The system of claim 20, wherein the local communications network is an Ethernet.

22. The system of claim 20, wherein the local communications network is a wireless network.

23. The system of claim 20, wherein the controller communicates with a remotely-located controller using a communications network and reports an occurrence of the thermal-runaway-condition-.

24. The system of claim 23, wherein the communications network is the Internet.

25. The system of claim 1, wherein a thermal-runaway-condition-related alarm indication is displayed by an indicator device.

26. The system of claim 1, wherein the battery string is a plurality of rechargeable batteries connected in series, and a plurality of battery strings are connected in parallel to supply electrical power to a load connectable to the battery system.

27. The system of claim 1, wherein the thermal runaway condition of a battery string of a plurality of battery strings is determined to exist when a time duration of a charging state of the battery string of the plurality of battery strings is greater than an expected time duration of the charging state, the expected time duration computed based on the characteristics of a preceding discharge state, and the expected time duration of the charging state is an average of the expected time durations of the charging state determined for each battery string of a plurality of battery strings.

28. A method of protecting a battery system, the method comprising:

measuring a current value of a battery string;

determining an operating state of the battery string using at least the measured current value;

comparing the measured current value of the battery string with an estimated float current in a fully charged state and a charging current time history in the charging state to determine whether the battery string has encountered a thermal runaway condition in either of the fully charged state or the charging state.

29. The method of claim 28, further comprising:

isolating a battery string encountering the thermal runaway condition from the battery charger, and the load a predetermined time after the thermal runaway condition has been determined.

30. The method of claim 29, wherein the step of isolating also isolates the battery string from other battery strings in a battery system comprising a plurality of battery strings connected in parallel.

31. The method of claim 28, further comprising:

transmitting a report message to a predetermined network address indicating that the battery string has encountered the thermal runaway condition.

32. The method of claim 28, further comprising:

sounding an aural alarm.

33. The method of claim 28, wherein threshold values exist for a warning condition and the thermal runaway condition, and a type of alarm indication represents the individual warning condition or the thermal runaway state in each of the charging and fully charged states.

34. The method of claim 28, further comprising:

estimating a time duration of a charging state after a discharge state as being proportional to a product of a time duration of a discharge state and an average discharge current of the battery string.

35. The method of claim 28, wherein the thermal runaway condition exists when the time duration of the charging state exceeds the estimated charging state duration.

36. The method of claim 28, wherein the thermal runaway condition exists in the fully charged state when the float current in a fully charged battery state is greater than a preset value proportional to the ampere hour rating of a battery of the battery string.

37. The method of claim 28, wherein the thermal runaway condition exists when the magnitude of the charging current reaches a minimum value, and the magnitude of the charging current increases with increasing time such that the magnitude of the charging current is greater than the magnitude of the minimum value of the charging current by a preset factor.

38. A non-transitory computer-readable medium storing a software program product, enabling a computer to perform the steps in a method, the method comprising:

accepting a current value measurement for a battery string in a battery system;

determining whether a battery in the battery string has encountered a thermal runaway condition; and

commanding a switch device to isolate the battery string from the battery system.

39. The non-transitory computer-readable medium of claim 38, wherein an alarm is output from the computer when the thermal runaway condition is encountered.

40. A battery system, comprising:

a current sensor, disposed so as to measure a value of current flowing in a battery string of the battery system;

a controller; and

a switch disposed in a series connection with the battery string;

wherein the battery system is operable in a discharging state, a charging state or a fully charged state, the controller is configured to compare the measured current value with an expected current value characteristic in the charging state to determine whether the battery string has encountered a thermal runaway condition, and to actuate the switch to isolate the battery string from the remainder of the battery system when the thermal runaway condition is determined.

41. The battery system of claim 40, wherein the expected current value characteristic for a thermal runaway condition is either of:

a magnitude of the current reaches a minimum value, and the magnitude of the current increases with increasing time such that the magnitude of the current is greater than the magnitude of the minimum value of the current by a preset factor;

or

a magnitude of the current is greater than a predetermined percentage of an ampere-hour (AH) rating of a battery of the battery string in amperes after a charging time that is greater than a computed estimate of a charging time based on the duration of the preceding discharge state and a current of the discharge state.