Battery pack maintenance for electric vehicles

• US 8,738,309 B2
• Filed: 09/30/2010
• Issued: 05/27/2014
• Est. Priority Date: 09/30/2010
• Status: Active Grant

• Current Assignee: Midtronics Incorporated
• Original Assignee: Midtronics Incorporated
• Inventors: Bertness, Kevin I.
• Primary Examiner(s): LE, TOAN M
• Application Number:
  US12/894,951
• Publication Number:
  US 20120079710A1
• Time in Patent Office: 1,335 Days
• Field of Search: 702/63, 702 57- 60, 702 64- 76, 702/81, 702/84, 702/108, 702/115, 702/127, 702182-185, 702188-189, 320/106, 320109-110, 320/112, 320/124, 320/137, 324/426, 324429-430, 324433-434, 324444-447, 340/635, 340/636.1, 34063612-63613, 340/636.15, 340/636.19
• US Class Current: 702/63
• CPC Class Codes: B60L 2240/545 Temperature
• 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 50/62 charged by low-power generators primarily intended to support the batteries, e.g. range extenders
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 53/65 involving identification of vehicles or their battery types
• CPC Class Codes: B60L 53/80 Exchanging energy storage elements, e.g. removable batteries
• CPC Class Codes: B60L 58/12 responding to state of charge [SoC]
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/21 having the same nominal voltage
• CPC Class Codes: H01M 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• 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
• CPC Class Codes: Y02T 90/167 Systems integrating technologies related to power network operation and communication or information technologies for supporting the interoperability of electric or hybrid vehicles, i.e. smartgrids as interface for battery charging of electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: Y04S 30/14 : Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing
• CPC Class Codes: Y10T 29/49004 : including measuring or testing of device or component part

Abstract

A method of repairing a used battery pack from an electric vehicle include removing the battery pack from the vehicle. Battery tests are performed on at least some of the plurality of batteries and a battery test result for each of the batteries tested are obtained and stored in a database. A plurality of replacement batteries are tested and test results for each of the replacement batteries are stored in the database. The battery test results from the database are retrieved and used to create a refurbished battery pack. An apparatus includes a database for storing test results.

Claims

1. A method of repairing a used battery pack from an electric vehicle, comprising:

removing the battery pack from the vehicle, the battery pack comprising a plurality of batteries;

performing battery tests with a battery tester on at least some individual batteries of the plurality of batteries, obtaining a battery test result for the batteries tested and storing the battery test results in a database;

obtaining a plurality of replacement batteries;

performing battery tests with a battery tester on at least some individual batteries of the plurality of the replacement batteries, obtaining a test result for the replacement batteries and storing the battery test results in the database;

retrieving the battery test results from the database;

identifying replacement batteries based upon the retrieved battery test results for use in forming a refurbished battery pack; and

refurbishing the battery pack with identified replacement batteries based upon the step of identifying.

2. The method of claim 1 wherein the step of identifying batteries comprises applying selection criteria to the battery test results stored in the database.

3. The method of claim 2 wherein the selection criteria is based upon an adjustable parameter of the batteries, the method further including adjusting the adjustable parameter of at least one battery.

4. The method of claim 2 wherein the selection criteria is based upon an adjustable parameter of the batteries, wherein the selection criteria applies a greater weighting function to a non-adjustable parameter relative to a nonadjustable parameter.

5. The method of claim 2 wherein the selection criteria includes comparing parameters of batteries to each other and identifying parameters which are within a selected range.

6. The method of claim 2 wherein the selection criteria is based upon multiple parameters of the batteries.

7. The method of claim 1 including storing battery identification information in the database which is associated with a test result for a particular battery.

8. The method of claim 1 including implementing the database in a computer memory.

9. The method of claim 1 wherein the battery test comprise applying a forcing function to a battery and observing a result.

10. The method of claim 1 wherein the batteries comprise individual cells.

11. The method of claim 1 wherein the batteries comprise groups of cells.

12. The method of claim 1 wherein performing battery tests on the batteries in the battery pack is performed prior to removing the battery pack from the vehicle.

13. The method of claim 1 wherein performing battery tests on the batteries in the battery pack is performed subsequent to removing the battery pack from the vehicle.

14. The method of claim 1 wherein the replacement batteries are obtained from another battery pack.

15. The method of claim 1 wherein the replacement batteries comprise new batteries.

16. The method of claim 1 including identifying a configuration of batteries for placement in the refurbished battery pack based upon the battery test results.

17. The method of claim 1 including implementing the step of identifying in a computer.

18. An apparatus for use in refurbishing a used battery pack from the electric vehicle, comprising:

battery test circuitry configured to perform battery tests on individual batteries in the used battery pack;

a database configured to contain battery identification information of a plurality of individual replacement batteries and at least one associated battery parameter obtained from the battery test circuitry;

a selection criteria which identifies individual replacement batteries for use in creating a refurbished battery pack; and

a controller configured to retrieve information from the database, apply the selection criteria and responsively provide selection information output which indicates which of the individual replacement batteries identified in the database are suitable for use in creating a refurbished battery pack.

19. The apparatus of claim 18 wherein the selection criteria includes comparing parameters of batteries to each other and identifying parameters which are within a selected range.

20. The apparatus of claim 19 wherein the selection criteria is based upon an adjustable parameter of the batteries, the controller further configured to adjust the adjustable parameter of at least one battery.

21. The apparatus of claim 19 wherein the selection criteria is based upon an adjustable parameter of the batteries, wherein the selection criteria applies a greater weighting function to a non-adjustable parameter relative to the adjustable parameter.

22. The apparatus of claim 18 wherein the selection criteria is based upon multiple parameters of the batteries.

23. The apparatus of claim 18 wherein the database includes battery identification information associated with a test result for a particular battery.

24. The apparatus of claim 18 wherein the battery test comprises applying a forcing function to a battery and observing a result.

25. The apparatus of claim 18 wherein the batteries comprise individual cells.

26. The apparatus of claim 18 wherein the batteries comprise groups of cells.

27. The apparatus of claim 18 wherein the selection information output includes information identifying a configuration of batteries for placement in the refurbished battery pack based upon the battery test results.