Health management of rechargeable batteries

• US 8,890,480 B2
• Filed: 11/30/2006
• Issued: 11/18/2014
• Est. Priority Date: 11/30/2006
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Vian, John L., Mansouri, Ali R., Elangovan, Rangasamy, Borumand, Mori M., Abdel-Motagaly, Khaled
• Primary Examiner(s): Tso, Edward
• Assistant Examiner(s): TORRES RUIZ, JOHALI ALEJANDRA
• Application Number:
  US11/565,574
• Publication Number:
  US 20100121587A1
• Time in Patent Office: 2,910 Days
• Field of Search: 320/132
• US Class Current: 320/132
• CPC Class Codes: B64D 45/00 Aircraft indicators or protectors not otherwise provided for camouflage F41H3/00
• CPC Class Codes: G01R 31/008 on air- or spacecraft, railway rolling stock or sea-going vessels
• CPC Class Codes: G01R 31/3647 for determining the ability of a battery to perform a critical function, e.g. cranking
• CPC Class Codes: G01R 31/367 Software therefor, e.g. for battery testing using modelling or look-up tables
• CPC Class Codes: G01R 31/3842 combining voltage and current measurements
• CPC Class Codes: G01R 31/392 Determining battery ageing or deterioration, e.g. state of health
• 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 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H02J 7/0014 Circuits for equalisation of charge between batteries
• CPC Class Codes: H02J 7/0029 with safety or protection devices or circuits
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

Systems and methods for health management of rechargeable batteries are disclosed. In one embodiment, a rechargeable battery system includes a rechargeable battery, and a battery health management unit operatively coupled to the rechargeable battery and including a state of health module configured to estimate a battery health by receiving battery-related data and predicting one or more failure modes. The state of health module may further include a prognostic failure mode component configured to combine at least one flight data variable with at least one model-based prognostic. In alternate embodiments, the battery health management unit may further include a state of life module and a state of charge module.

Claims

1. A system to monitor health of a rechargeable battery electrically coupled to an aircraft, the system comprising:

a vehicle portion, comprising;

a battery health management unit physically connected to the rechargeable battery by an internal data bus and including;

a state of charge module to estimate a state of battery charge of the rechargeable battery based on battery-related data received on the internal data bus;

a state of health module to estimate a state of battery health based on battery-related data received on the internal data bus, wherein the battery-related data comprises data collected in real time operation of the battery and fault history of the aircraft;

a state of life module to estimate a state of battery life of the rechargeable battery based on battery-related data received on the internal data bus; and

a prognostic management component to;

receive an output from at least one of the state of charge module, the state of health module, and the state of life module;

process the output to generate a health status indicator which provides a fix or fly status for the rechargeable battery; and

output the health status indicator to an external data bus separate from the internal data bus.

2. The system of claim 1, wherein the state of health module includes a prognostic failure mode component configured to generate a health-based prognosis based on at least one flight data variable and at least one model-based prognostic.

3. The system of claim 2, wherein the prognostic failure mode component generates the health-based prognosis based on an embedded failure mode from a Failure Modes and Effects Analysis (FMEA), signal processing of recorded battery-relevant flight data, a vehicle operation anomaly, a vehicle maintenance action, or combinations thereof.

4. The system of claim 1, wherein the state of life module receives one or more inputs from the state of health module and one or more inputs from the state of charge module to determine a remaining battery life.

5. The system of claim 4, wherein the state of life module determines the remaining battery life based on a correlation between a model-based analysis and a battery-relevant data including at least one of a voltage, a temperature, a current, a charge cycle, an operating time, a shelf time, and an onboard time.

6. The system of claim 4, wherein the state of life module determines the remaining battery life based on a model that uses a predetermined battery performance, a predetermined cycle life data, and an empirical test data.

7. The system of claim 4, wherein the state of health module receives an output from the state of life module, and performs an estimate of a state of health based on the output.

8. The system of claim 4, wherein the state of charge module determines a remaining battery capacity based on a discharge rate, a reference capacity, and a reference discharge rate.

9. The system of claim 4, wherein the state of life module receives an output from the state of health module and wherein the state of life module performs an estimate of a state of life based on the output.

10. The system of claim 1, further comprising:

a battery bus coupled to the rechargeable battery and to the battery health management unit;

a recharger coupled to the battery bus; and

at least one electrical load coupled to the battery bus.

11. The system of claim 1, wherein the external data bus comprises an instrumentation bus coupled to one or more instrumentation panels of the system.

12. The system of claim 11, wherein the instrumentation bus is coupled to an onboard health management system for an aircraft.

13. The system of claim 11, wherein the instrumentation bus is coupled to an on-ground health management system for an aircraft.

14. The system of claim 1, wherein the battery-related data is generated in real time operation of the battery during operation of the aircraft.

15. The system of claim 1, further comprising:

an off-vehicle portion comprising an off-vehicle health management system operatively coupled to a plurality of off-vehicle information and management systems, wherein the battery health management unit communicates the health status indicator to the off-vehicle health management system.

16. A method of determining a health characteristic of a rechargeable battery electrically coupled to a vehicle, the method comprising:

receiving, in a battery health management unit physically connected to the rechargeable battery, battery-related data on an internal data bus, wherein the battery-related data comprises data collected in real time operation of the rechargeable battery;

estimating a state of battery charge based on battery-related data received on the internal data bus;

estimating a state of battery health based on battery-related data received on the internal data bus, wherein the battery-related data comprises first data indicating one or more operation anomalies associated with the vehicle;

estimating a state of battery life based on battery-related data received on the internal data bus;

processing at least one of the state of battery charge, the state of battery health, and the state of battery life to generate a health status indicator which provides a fix or fly status for the rechargeable battery; and

outputting health status indicator onto an external data bus, separate from the internal data bus.

17. The method of claim 16, further comprising generating a health-based prognosis based on at least one flight data variable and at least one model-based prognostic.

18. The method of claim 17, wherein the health-based prognosis is generated based on an embedded failure mode from a Failure Modes and Effects Analysis (FMEA), signal processing of recorded battery-relevant flight data, a vehicle maintenance action, and a fault history.

19. The method of claim 17, further comprising:

receiving battery-relevant data into a state of life module coupled to the rechargeable battery, wherein the battery-relevant data comprises real-time data relating to varying rates of discharge of the rechargeable battery during use and varying depths of discharge of the rechargeable battery during use;

predicting a remaining battery life based on a correlation between a model-based analysis and the battery-relevant data; and

wherein estimating a battery health includes estimating the battery health based on one or more failure modes and the remaining battery life.

20. The method of claim 16, wherein the rechargeable battery is a component of an aircraft and wherein the battery related data is generated in real time operation of the rechargeable battery during operation of the aircraft.

21. The method of claim 16, further comprising:

communicating the health status indicator to an off-vehicle portion comprising an off-vehicle health management system operatively coupled to a plurality of off-vehicle information and management systems.