Secondary service port for high voltage battery packs

• US 9,263,901 B2
• Filed: 03/04/2013
• Issued: 02/16/2016
• Est. Priority Date: 05/19/2012
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Boggs, Brian Stuart, Darragh, Joseph Michael, Goldman, Mark D.
• Primary Examiner(s): Grant, Robert
• Application Number:
  US13/784,458
• Publication Number:
  US 20130307478A1
• Time in Patent Office: 1,079 Days
• Field of Search: 320/109, 320/112
• US Class Current: 1/1
• CPC Class Codes: B60L 3/00 Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption methods or circuit arrangements for monitoring or controlling batteries or fuel cells B60L58/00
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/60 Monitoring or controlling charging stations
• CPC Class Codes: B60L 58/10 for monitoring or controlling batteries
• 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 58/26 by cooling
• CPC Class Codes: G01R 31/36 Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

A system and method for providing energy management and maintenance of a high energy battery pack that does not require installation of the battery pack into an operational EV. A secondary service port is provided to enable certain maintenance operations while by-passing battery pack interlocks and protection mechanisms used when the battery pack is installed into an operating environment.

Claims

1. A rechargeable high-voltage battery pack, comprising:

a plurality of series-coupled energy storage elements;

an interlock having a first node and a second node, said first node coupled to said plurality of series-coupled energy storage elements with said interlock responsive to a control signal to control a power communication of said first node to said second node, said interlock enabling said communication with said control signal in a first mode and said interlock disabling said power communication with said control signal in a second mode;

a housing enclosing and sealing said plurality of series-coupled energy storage elements and said interlock with a plurality of exterior walls;

an operational port coupled to a portion of a first particular one exterior wall of said plurality of exterior walls, said operational port coupled to said second node and providing a first energy transfer with respect to said plurality of series-coupled energy storage elements only when said power communication is enabled; and

a service port coupled to a portion of a second particular one exterior wall of said plurality of exterior walls, said service port coupled to said first node and providing a second energy transfer with respect to said plurality of series-coupled energy storage elements without regard to whether said power communication is enabled;

wherein said service port includes an energy transfer direction control limiting said second energy transfer to a single direction, and wherein said single direction discharges said a plurality of series-coupled energy storage elements through said service port.

2. The rechargeable high-voltage battery pack of claim 1 further comprising a battery management system selectively asserting said control signal.

3. The rechargeable high-voltage battery pack of claim 2 wherein said interlock includes a plurality of contactors selectively opening and closing responsive to said control signal, said plurality of contactors closed to enable said power communication and open to disable said power communication.

4. The rechargeable high-voltage battery pack of claim 1 further comprising an operating environment supporting said housing, said operating environment including:

a primary charging connector;

a first electro-mechanical interface coupling said primary charging connector to said operational port;

a secondary charging connector; and

a second electro-mechanical interface coupling said secondary charging connector to said service port.

5. The rechargeable high-voltage battery pack of claim 4 further comprising a battery management system selectively asserting said control signal.

6. The rechargeable high-voltage battery pack of claim 5 wherein said interlock includes a plurality of contactors selectively opening and closing responsive to said control signal, said plurality of contactors closed to enable said power communication and open to disable said power communication.

7. The rechargeable high-voltage battery pack of claim 6 wherein said battery management system includes an electronic lock responsive to a digital signature, said electronic lock inhibiting assertion of said control signal absent an assertion of said digital signal to said battery management system.

8. The rechargeable high-voltage battery pack of claim 7 wherein said operating environment asserts said digital signature to said battery management system.

9. The rechargeable high-voltage battery pack of claim 4 including a tamper-evident seal coupled to said secondary charging connector with said tamper-evident seal visually indicating use of said service port.

10. A method for managing a rechargeable high-voltage battery pack, comprising:

a) configuring the rechargeable high-voltage battery pack to transfer energy with respect to an exterior operational port through an interlock; and

b) bypassing said interlock to transfer energy between the rechargeable high-voltage battery pack and an exterior service port without using said operational port to transfer energy relative to the rechargeable high-voltage battery pack;

wherein said exterior service port includes an energy transfer direction control limiting said transfer of energy to a single direction, and wherein said single direction discharges said rechargeable high-voltage battery pack through said exterior service port.

11. The method of claim 10 wherein said operational port supports bidirectional energy transfers with respect to the rechargeable high-voltage battery pack, further comprising:

c) limiting said transfer of energy of said bypassing step to the single direction only.

12. The method of claim 10 wherein the rechargeable high-voltage battery pack is installed in an operating environment, said operating environment including a primary exterior-accessible power connector communicated to said operational port and a secondary exterior-accessible power connector communicated to said service port.

13. The method of claim 12 further comprising:

d) protecting said secondary exterior-accessible power connector using a tamper-evident closure that provides a visual indication of a use of said service port.