Short detection in battery cells

• US 9,097,774 B2
• Filed: 07/14/2011
• Issued: 08/04/2015
• Est. Priority Date: 07/14/2011
• Status: Active Grant

• Current Assignee: Southwest Electronic Energy Corporation (Ultralife Corporation)
• Original Assignee: Southwest Electronic Energy Corporation (Ultralife Corporation)
• Inventors: White, David A., Benckenstein, Claude L. Jr.
• Primary Examiner(s): Kundu, Sujoy
• Assistant Examiner(s): Casey, Liam R
• Application Number:
  US13/182,998
• Publication Number:
  US 20130018606A1
• Time in Patent Office: 1,482 Days
• Field of Search: 702/58, 702/63, 320/119
• US Class Current: 1/1
• CPC Class Codes: G01R 31/392 Determining battery ageing or deterioration, e.g. state of health
• 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: G01R 31/52 Testing for short-circuits, leakage current or ground faults
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H02J 7/0014 Circuits for equalisation of charge between batteries

Abstract

Internal shorts and other failures in lithium-ion battery cells may be detected during balancing of the battery cells. A counter may be used to detect when a battery cell is behaving differently than other battery cells by balancing more or less frequently. The counter may increment each time a battery cell is balanced to the other battery cells. A misbehaving battery cell may be flagged, when the counter exceeds a threshold value, for safety checks before an overheating event occurs. This misbehaving battery cell may be faulty due to an internal short. If the faulty battery cell is not corrected by replacement with a different battery cell or corrected by a user resetting the counter, the misbehaving battery cell may be disconnected to prevent the overheating event.

Claims

1. A method, comprising:

monitoring, by a microprocessor, a plurality of battery cells through circuitry coupled to the plurality of battery cells to monitor at least one of a voltage across at least one of the plurality of battery cells and a current through at least one of the plurality of battery cells;

counting, by the microprocessor, a first number of times a first battery cell of the plurality of battery cells is out of balance with other battery cells of the plurality of battery cells, wherein the step of counting comprises determining whether the first battery cell is out of balance with the other battery cells by comparing a relative state of charge of the first battery cell with a relative state of charge of at least one of the other battery cells, wherein the relative state of charge of the first battery cell and the at least one of the other battery cells is determined based, at least in part, on the step of monitoring the plurality of battery cells;

counting, by the microprocessor, a second number of times a second battery cell of the plurality of battery cells is out of balance with other battery cells of the plurality of battery cells, wherein the step of counting comprises determining whether the second battery cell is out of balance with the other battery cells by comparing a relative state of charge of the second battery cell with a state of charge of at least one of the other battery cells; and

marking, by the microprocessor, the first battery cell as potentially faulty due to an internal short based, at least in part, on the first count exceeding a first threshold,

wherein the first threshold, for marking the first battery cell as potentially faulty due to an internal short is based at least in part on the second count.

2. The method of claim 1, further comprising:

storing a time associated with the first count when the first battery cell is out of balance with the other battery cells, the time indicating when the first battery cell is out of balance with the other battery cells; and

storing a quantity associated with the first count when the first battery cell is out of balance with the other battery cells, the quantity indicating a charge difference between the first battery cell and the other battery cells,

in which marking the first battery cell as potentially faulty is also based, at least in part, on the time and quantity of each counted time the first battery cell is out of balance with the other battery cells.

3. The method of claim 2, in which marking the first battery cell as potentially faulty comprises comparing the first counted number of times, quantity information, and time information with at least one known historical profile of a potentially faulty battery cell.

4. The method of claim 1, in which the step of monitoring the plurality of battery cells comprises monitoring battery cells in a plurality of battery pack system modules, and the method further comprises replacing at least one battery pack system module of the plurality of battery pack system modules containing the at least one battery cell marked as potentially faulty.

5. The method of claim 1, further comprising:

transmitting a message to a user that the first battery cell is potentially faulty; and

disconnecting the first battery cell after marking the first battery cell.

16. The method of claim 1, further comprising:

monitoring a temperature of the first battery cell marked as potentially faulty; and

when the temperature of the first battery cell increases, marking the first battery cell as faulty.

19. The method of claim 1, wherein the step of comparing a relative state of charge of the first battery cell with a relative state of charge of at least one of the other battery cells comprises comparing a voltage at terminals of the first battery cell with a voltage at terminals of at least one of the other battery cells.

22. The method of claim 1, wherein the step of counting the first number of times comprises:

determining whether the first battery cell is at a lower or higher state of charge than the other battery cells;

when the first battery cell is at a lower state of charge than the other battery cells, incrementing the first number of times; and

when the first battery cell is at a higher state of charge than the other battery cells, not incrementing the first number of times.

6. A computer program product, comprising:

a non-transitory computer-readable medium comprising;

code to instruct a microprocessor to monitor, through circuitry coupled to a plurality of battery cells, at least one of a voltage across at least one of the plurality of battery cells and a current through at least one of the plurality of battery cells;

code to count a first number of times a first battery cell of the plurality of battery cells is out of balance with other battery cells of the plurality of battery cells, wherein the code to count the first number of times comprises code to determine whether the first battery cell is out of balance with the other battery cells by comparing a relative state of charge of the first battery cell with a relative state of charge of at least one of the other battery cells, wherein the state of charge of the first battery cell and the at least one of the other battery cells is based, at least in part, on the at least one of a voltage across at least one of a plurality of battery cells and a current through at least one of the plurality of battery cells;

code to count a second number of times a second battery cell of the plurality of battery cells is out of balance with other battery cells of the plurality of battery cells, wherein the code to count comprises code to determine whether the second battery cell is out of balance with the other battery cells by comparing a relative state of charge of the second battery cell with a relative state of charge of at least one of the other battery cells; and

code to mark the first battery cell as potentially faulty due to an internal short based, at least in part, on the first count exceeding a first threshold,

wherein the first threshold, for marking the first battery cell as potentially faulty due to an internal short is based at least in part on the second count.

7. The computer program product of claim 6, in which the medium further comprises:

code to store a time associated with the first count when the first battery cell is out of balance with the other battery cells, the time indicating when the first battery cell is out of balance with the other battery cells; and

code to store a quantity associated with the first count when the first battery cell is out of balance with the other battery cells, the quantity indicating a charge difference between the first battery cell and the other battery cells,

in which marking the first battery cell as potentially faulty is also based, at least in part, on the time and quantity of each counted time the first battery cell is out of balance with the other battery cells.

8. The computer program product of claim 7, in which the medium further comprises code to compare the first counted number of times, quantity information, and time information with at least one known historical profile of a potentially faulty battery cell.

9. The computer program product of claim 6, in which the medium further comprises:

code to disconnect the first battery cell after marking the first battery cell; and

code to transmit a message to a user that the first battery cell is potentially faulty.

17. The computer program product of claim 6, further comprising:

code to monitor a temperature of the first battery cell marked as potentially faulty; and

code to mark the first battery cell as faulty when the temperature of the first battery cell increases.

20. The computer program product of claim 6, wherein the step of comparing a relative state of charge of the first battery cell with a relative state of charge of at least one of the other battery cells comprises comparing a voltage at terminals of the first battery cell with a voltage at terminals of at least one of the other battery cells.

23. The computer program product of claim 6, wherein the code to count the first number of times comprises code to perform the steps of:

determining whether the first battery cell is at a lower or higher state of charge than the other battery cells;

when the first battery cell is at a lower state of charge than the other battery cells, incrementing the first number of times; and

when the first battery cell is at a higher state of charge than the other battery cells, not incrementing the first number of times.

10. An apparatus, comprising:

a plurality of battery cells;

circuitry coupled to the plurality of battery cells configured to measure at least one of a current through at least one of the plurality of battery cells and a voltage across at least one of the plurality of battery cells; and

a microprocessor coupled to the plurality of battery cells through the circuitry, in which the microprocessor is configured;

to monitor at least one of a voltage across at least one of the plurality of battery cells and a current through at least one of the plurality of battery cells;

to count a first number of times a first battery cell of the plurality of battery cells is out of balance with other battery cells of the plurality of battery cells, wherein the microprocessor is configured to determine whether the first battery cell is out of balance with the other battery cells by comparing a relative state of charge of the first battery cell with a relative state of charge of at least one of the other battery cells, wherein the microprocessor is configured to determine a relative state of charge of the first battery cell and the at least one of the other battery cells based, at least in part, on the monitored at least one of a voltage across at least one of the plurality of battery cells and a current through at least one of the plurality of battery cells;

to count a second number of times a second battery cell of the plurality of battery cells is out of balance with other battery cells of the plurality of battery cells, wherein the microprocessor is further configured to determine whether the second battery cell is out of balance with the other battery cells by comparing a relative state of charge of the second battery cell with a relative state of charge of at least one of the other battery cells; and

to mark the first battery cell as potentially faulty due to an internal short based, at least in part, on the first count exceeding a first threshold,

wherein the first threshold, for marking the first battery cell as potentially faulty due to an internal short is based at least in part on the second count.

11. The apparatus of claim 10, in which the microprocessor is further configured:

to store a time associated with the first count when the first battery cell is out of balance with the other battery cells, the time indicating when the first battery cell is out of balance with the other battery cells; and

to store a quantity associated with the first count when the first battery cell is out of balance with the other battery cells, the quantity indicating a charge difference between the first battery cell and the other battery cells,

in which marking the first battery cell as potentially faulty is also based, at least in part, on the time and quantity of each counted time the first battery cell is out of balance with the other battery cells.

12. The apparatus of claim 11, in which marking the first battery cell as potentially faulty comprises comparing the first counted number of times, quantity information, and time information with at least one known historical profile of a potentially faulty battery cell.

13. The apparatus of claim 10, in which the microprocessor is further configured to transmit a message to a user that the first battery cell is potentially faulty.

14. The apparatus of claim 10, in which the microprocessor is further configured to disconnect the first battery cell marked as potentially faulty.

15. The apparatus of claim 10, in which the plurality of battery cells and the microprocessor comprises a battery pack system module.

18. The apparatus of claim 10, in which the microprocessor is further configured:

to monitor a temperature of the first battery cell marked as potentially faulty; and

to mark the first battery cell as faulty when the temperature of the first battery cell increases.

21. The apparatus of claim 10, wherein the step of comparing a relative state of charge of the first battery cell with a relative state of charge of at least one of the other battery cells comprises comparing a voltage at terminals of the first battery cell with a voltage at terminals of at least one of the other battery cells.

24. The apparatus of claim 10, wherein the microprocessor is configured to count by performing the steps of:

determining whether the first battery cell is at a lower or higher state of charge than the other battery cells;

when the first battery cell is at a lower state of charge than the other battery cells, incrementing the first number of times; and

when the first battery cell is at a higher state of charge than the other battery cells, not incrementing the first number of times.