Response to over-current in a battery pack

• US 9,257,729 B2
• Filed: 11/25/2013
• Issued: 02/09/2016
• Est. Priority Date: 01/05/2012
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Hermann, Weston A., Kohn, Scott I.
• Primary Examiner(s): BUTLER, RODNEY ALLEN
• Application Number:
  US14/089,702
• Publication Number:
  US 20140088809A1
• Time in Patent Office: 806 Days
• Field of Search: 701/22, 180/65.29, 429/50, 429/61, 429/62, 903/907
• US Class Current: 1/1
• 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 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 58/13 Maintaining the SoC within a determined range
• CPC Class Codes: B60L 58/14 Preventing excessive discharging
• CPC Class Codes: B60L 58/15 Preventing overcharging
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/22 Balancing the charge of battery modules
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/60 Heating or cooling; Temperature control
• 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 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10S 903/907 Electricity storage, e.g. battery, capacitor

Abstract

A controller identifies a condition of a hazardous internal short by comparing patterns of series element voltages to the last known balance condition of the series elements. If the loaded or resting voltage of one or more contiguous series elements uniformly drop from the previously known condition by an amount consistent with an over-current condition, an over-current internal short circuit fault is registered. The desired response is to prevent the affected series elements from heating to a hazardous temperature by summoning the maximum heat rejection capability of the system until the short ceases and the affected elements cool, the cooling function is no longer able to operate due to low voltage, or the affected series string has drained all of its energy through the short. Also includes are responses that allow the battery pack to continue to power the cooling system even though it may enter an over-discharged state.

Claims

1. A microprocessor-implemented response system for an over-current internal short in an battery pack, comprising:

means for monitoring an over-current internal short flag indicative of a possible over-current internal short within a plurality of electrically-serially-coupled battery elements storing energy for the battery pack; and

means, coupled to said battery elements and responsive to said possible over-current internal short flag when said means for monitoring detects a likelihood of said possible over-current internal short, for decreasing risks associated with said possible over-current internal short when operated, the means for decreasing risks comprising a coolant distribution system thermally coupled to said battery elements, operable using energy from the battery pack or an auxiliary power source, and wherein said means for decreasing risks operates said coolant distribution system until said coolant distribution system has insufficient energy to operate;

wherein said battery pack performs self-protection from over-discharge by stopping power to said coolant distribution system when available energy falls below an under-energy threshold, wherein said means for decreasing risks overrides said self-protection and enables operation of said coolant distribution system below said under-energy threshold.

2. The response system of claim 1, the means for decreasing risks comprising a coolant distribution system thermally coupled to said battery elements wherein said means for decreasing risks operates said coolant distribution system until said over-current internal short flag no longer indicates said possible over-current internal short.

3. The response system of claim 1 wherein the over-current internal short in the battery pack spans a set of said plurality of battery elements, the means for decreasing risks including a coolant distribution system removing heat from said set of battery elements, and wherein said means for decreasing risks operates said coolant distribution system until said set of battery elements are below a SOC (state of charge) where further heating is no longer considered to be a risk.

4. The response system of claim 1 wherein the over-current internal short in the battery pack spans a set of said plurality of battery elements, the means for decreasing risks including a coolant distribution system removing heat from said set of battery elements, and wherein said means for decreasing risks operates said coolant distribution system until all useable energy stored in said set of battery elements is dissipated.

5. The response system of claim 1 wherein the battery pack is installed in an electric vehicle as a traction battery and wherein said means for decreasing risks initiates a discontinuation of drive energy to the electric vehicle from the battery pack responsive to said possible over-current internal short flag.

6. A microprocessor-implemented response system for an over-current internal short in an battery pack, comprising:

means for monitoring an over-current internal short flag indicative of a possible over-current internal short within a plurality of electrically-serially-coupled battery elements storing energy for the battery pack; and

means, coupled to said battery elements and responsive to said possible over-current internal short flag when said means for monitoring detects a likelihood of said possible over-current internal short, for decreasing risks associated with said possible over-current internal short when operated;

wherein the over-current internal short in the battery pack spans a set of said plurality of battery elements, wherein said set of battery elements includes a series-coupled current protection device that interrupts an over-current flowing in the over-current internal short, and wherein said means for decreasing risks triggers said series-coupled current protection device responsive to said possible over-current internal short flag to interrupt said over-current.

7. The response system of claim 6 wherein the series-coupled current protection device includes different modes of operation for triggering.

8. The response system of claim 6 wherein the series-coupled current protection device includes a current interrupter coupled in series with at least one series element, the series element providing data for operation of the current interrupter.

9. The response system of claim 7 wherein the different modes are set by a controller that is separate from the series-coupled current protection device.

10. The response system of claim 7 wherein the series-coupled current protection device is at least partially autonomous.

11. A computer-implemented method for responding to an over-current internal short in an battery pack, the method comprising the steps of:

a) monitoring, using a microprocessor, an over-current internal short flag indicative of a possible over-current internal short within a plurality of electrically-coupled battery elements storing energy for the battery pack; and

thereafter

b) activating means, coupled to said plurality of battery elements, with said means responsive to said possible over-current internal short flag when said means for monitoring detects a likelihood of said possible over-current internal short, for decreasing risks associated with said possible over-current internal short when operated, wherein the battery pack includes a coolant distribution system, operable using energy from the battery pack, said coolant distribution system removing heat from said plurality of battery elements and wherein said means for decreasing risks operates said coolant distribution system until said coolant distribution system has insufficient energy from the battery pack to operate;

wherein said battery pack performs self-protection from over-discharge by stopping power to said coolant distribution system when available energy from the battery pack falls below an under-energy threshold, wherein said means for decreasing risks overrides said self-protection and enables operation of said coolant distribution system below said under-energy threshold.

12. The responding method of claim 11 wherein the battery pack includes a coolant distribution system removing heat from the plurality of battery elements and wherein said means for decreasing risks operates said coolant distribution system until said over-current internal short flag no longer indicates said possible over-current internal short.

13. The responding method of claim 11 wherein the over-current internal short in the battery pack spans a set of said plurality of battery elements, wherein the battery pack includes a coolant distribution system, operable using energy from the battery pack, removing heat from said set of battery elements, and wherein said means for decreasing risks operates said coolant distribution system until said set of battery elements are below a SOC (state of charge) where further heating is no longer a risk.

14. The responding method of claim 11 wherein the over-current internal short in the battery pack spans a set of said plurality of battery elements, wherein the battery pack includes a coolant distribution system removing heat from said set of battery elements, and wherein said means for decreasing risks operates said coolant distribution system until all useable energy stored in said set of battery elements is dissipated.

15. The responding method of claim 11 wherein the battery pack is installed in an electric vehicle as a traction battery and wherein said means for decreasing risks initiates a discontinuation of drive energy to the electric vehicle from the battery pack responsive to said possible over-current internal short flag.

16. A computer-implemented method for responding to an over-current internal short in an battery pack, the method comprising the steps of:

a) monitoring, using a microprocessor, an over-current internal short flag indicative of a possible over-current internal short within a plurality of electrically-coupled battery elements storing energy for the battery pack; and

thereafter

b) activating means, coupled to said plurality of battery elements, with said means responsive to said possible over-current internal short flag when said means for monitoring detects a likelihood of said possible over-current internal short, for decreasing risks associated with said possible over-current internal short when operated,

wherein the over-current internal short in the battery pack spans a set of said plurality of battery elements, wherein said set of battery elements includes a series-coupled current protection device that interrupts a current flowing in the over-current internal short, and wherein said means for decreasing risks triggers said series-coupled current protection device responsive to said possible over-current internal short flag to interrupt said current.