Plug-in bussed electrical center for an energy storage system

• US 8,728,642 B2
• Filed: 06/06/2012
• Issued: 05/20/2014
• Est. Priority Date: 12/07/2010
• Status: Active Grant

• Current Assignee: Allison Transmission Incorporated (Allison Transmission Holdings Incorporated)
• Original Assignee: Allison Transmission Incorporated (Allison Transmission Holdings Incorporated)
• Inventors: Morrow, Brian C., Maskew, Brian J., Gasaway, Timothy A.
• Primary Examiner(s): Ryan, Patrick
• Assistant Examiner(s): DOMONE, CHRISTOPHER P
• Application Number:
  US13/490,029
• Publication Number:
  US 20120244398A1
• Time in Patent Office: 713 Days
• Field of Search: None
• US Class Current: 429/61
• CPC Class Codes: B60K 2006/4825 Electric machine connected or connectable to gearbox input shaft
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 15/2054 by controlling transmissions or clutches
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2240/26 Vehicle weight
• CPC Class Codes: B60L 2240/421 Speed
• 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 2250/12 by confirmation, e.g. of the input
• CPC Class Codes: B60L 2250/16 by display
• CPC Class Codes: B60L 2270/145 Structure borne vibrations
• 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 3/0084 relating to control modules
• CPC Class Codes: B60L 3/108 whilst braking, i.e. ABS
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/30 : using propulsion power stored mechanically, e.g. in fly-wheels
• 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 58/12 : responding to state of charge [SoC]
• CPC Class Codes: B60L 58/20 : having different nominal voltages
• CPC Class Codes: B60L 58/21 : having the same nominal voltage
• CPC Class Codes: B60L 58/26 : by cooling
• CPC Class Codes: B60Y 2400/112 : Batteries
• CPC Class Codes: F28F 9/00 : Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
• CPC Class Codes: G01K 1/146 : arrangements for moving thermometers to or from a measuring position
• 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 10/482 : for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/486 : for measuring temperature
• CPC Class Codes: H01M 10/613 : Cooling or keeping cold
• CPC Class Codes: H01M 10/617 : for achieving uniformity or desired distribution of temperature
• CPC Class Codes: H01M 10/625 : Vehicles
• CPC Class Codes: H01M 10/637 : characterised by the use of reversible temperature-sensitive devices, e.g. NTC, PTC or bimetal devices; characterised by control of the internal current flowing through the cells, e.g. by switching means for preventing undesired use or discharge H01M50/572
• CPC Class Codes: H01M 10/6551 : Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• CPC Class Codes: H01M 10/6554 : Rods or plates
• CPC Class Codes: H01M 10/6563 : with forced flow, e.g. by blowers
• CPC Class Codes: H01M 10/658 : by thermal insulation or shielding
• 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 2200/00 : Safety devices for primary or secondary batteries
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/204 : Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/244 : Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• 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 50/289 : characterised by spacing elements or positioning means within frames, racks or packs spacing elements inside cells other than separators, membranes or diaphragms H01M50/471
• CPC Class Codes: H01M 50/30 : Arrangements for facilitating escape of gases
• CPC Class Codes: H01M 50/317 : Re-sealable arrangements
• 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 50/574 : Devices or arrangements for the interruption of current
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• 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: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y10S 903/907 : Electricity storage, e.g. battery, capacitor

Abstract

An energy storage system comprising at least one energy storage module adapted to supply electrical energy to a hybrid vehicle. The energy storage module comprises an enclosure, at least one battery array located within the enclosure, and an energy storage controller module located within the enclosure and electrically connected to the battery array. A high voltage junction box is attached to a first end of the enclosure and having a plurality of high voltage connection terminals connected by a plug-in bussed electrical center configured to reduce the possibility of unintentional grounding or shorting, and decreases the safety risk to a technician during servicing. At least one of the high voltage connection terminals is configured to receive a high voltage conductor connected between the energy storage module and an inverter of the hybrid vehicle.

Claims

1. An energy storage system, comprising:

an energy storage module having a potential difference of at least 300 volts adapted to supply electrical energy to a hybrid vehicle, the energy storage module including

a primary enclosure;

a battery array located within the primary enclosure, the battery array having a plurality of battery cells;

a high-voltage junction box mounted to the primary enclosure, the high-voltage junction box including at least one internal terminal electrically connected to the battery array by a plurality of internal high-voltage conductors, the high-voltage junction box also having at least one external terminal configured to electrically connect to at least one external high-voltage conductor; and

a plug-in bussed electrical center formed of electrically insulative material and mounted in the high-voltage junction box, the plug-in bussed electrical center also having;

one or more high-voltage contactors;

at least one internal terminal connector rigidly extending away from the plug-in bussed electrical center and configured to electrically connect to the corresponding at least one internal terminal in the high-voltage junction box; and

at least one external terminal connector rigidly extending away from the plug-in bussed electrical center and configured to electrically connect to the corresponding at least one external terminal in the high-voltage junction box;

wherein the plug-in bussed electrical center is configured to electrically connect one or more of the internal terminal connectors with one or more of the external terminal connectors using the one or more high-voltage contactors.

2. The energy storage system of claim 1 wherein the at least one internal terminal is adapted to receive the corresponding at least one internal terminal connector, and the at least one external terminal is adapted to receive the at least one external terminal connector.

3. The energy storage system of claim 1 wherein the at least one internal terminal connector and the at least one external terminal connector are bus bar blade connectors.

4. The energy storage system of claim 1 wherein the plug-in bussed electrical center further comprises a current sensor.

5. The energy storage system of claim 4 wherein the plug-in bussed electrical center further comprises a current sensor connector which is electrically connected to the current sensor.

6. The energy storage system of claim 1 wherein the plug-in bussed electrical center further comprises a fuse.

7. The energy storage system of claim 1 wherein the plug-in bussed electrical center further comprises a high voltage sense connector.

8. The energy storage system of claim 1 wherein the plug-in bussed electrical center further comprises a low voltage connector.

17. The energy storage system of claim 1 wherein the energy storage system has two or more energy storage modules electrically connected to the energy storage system in parallel.

18. The energy storage system of claim 1 wherein the energy storage system has two or more energy storage modules electrically connected to the energy storage system in series.

9. A plug-in bussed electrical center for use in a hybrid vehicle, comprising:

a connector formed of electrically insulative material having a plurality of internal terminal connectors and a plurality of external terminal connectors; and

a plurality of high voltage contactors configured to electrically connect one or more of the internal terminal connectors with one or more of the external terminal connectors;

wherein the plurality of internal terminal connectors are configured to electrically connect to one or more corresponding internal terminals in a high-voltage junction box, and the plurality of external terminal connectors are configured to electrically connect to one or more corresponding external terminals in the high-voltage junction box;

wherein one or more of the internal terminal connectors, and one or more of the external terminal connectors rigidly extend away from the connector;

wherein the internal terminals are electrically connected to a first battery array having a plurality of battery cells, and

wherein the external terminals are electrically connected to an energy storage system for a hybrid vehicle drive system, the battery array having a potential difference of at least 300 volts.

10. The plug-in bussed electrical center of claim 9 wherein at least one of the corresponding internal terminals are adapted to receive at least one of the internal terminal connectors, and at least one of the corresponding external terminals are adapted to receive at least one of the external terminal connectors.

11. The plug-in bussed electrical center of claim 9 wherein at least one of the internal terminal connectors and at least one of the external terminal connectors are bus bar blade connectors.

12. The plug-in bussed electrical center of claim 9 further comprising a current sensor.

13. The plug-in bussed electrical center of claim 12 further comprising a current sensor connector which is electrically connected to the current sensor.

14. The plug-in bussed electrical center of claim 9 further comprising a fuse.

15. The plug-in bussed electrical center of claim 9 further comprising a high voltage sense connector.

16. The plug-in bussed electrical center of claim 9 further comprising a low voltage connector.

19. The plug-in bussed electrical center of claim 9 wherein the energy storage system includes a second battery array having a plurality of battery cells, the second battery array electrically connected to the first battery array in parallel.

20. The plug-in bussed electrical center of claim 9 wherein the energy storage system includes a second battery array having a plurality of battery cells, the second battery array electrically connected to the first battery array in series.