Energy storage systems and methods

• US 9,272,627 B2
• Filed: 08/23/2010
• Issued: 03/01/2016
• Est. Priority Date: 01/25/2010
• Status: Active Grant

• Current Assignee: UCAP Power, Inc.
• Original Assignee: Maxwell Technologies Incorporated (Tesla Inc.)
• Inventors: Miller, John M.
• Primary Examiner(s): Rodas, Richard Isla
• Assistant Examiner(s): Bui, Dung V
• Application Number:
  US13/574,706
• Publication Number:
  US 20120319471A1
• Time in Patent Office: 2,017 Days
• Field of Search: 320/166, 320/104, 307/9.1, 307/10.1, 324/426, 324/427, 324/433, 369/1, 180/2.2, 701/36
• US Class Current: 1/1
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2250/22 by presence detection
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 58/13 Maintaining the SoC within a determined range
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/25 by controlling the electric load
• 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 90/14 Plug-in electric vehicles

Abstract

In an energy storage system that includes a battery and an ultracapacitor, the state of charge (SOC) of the capacitor is the subject of a dynamic set-point. This dynamic set-point control is a function of the load regime to which the storage system is exposed, for example a hybrid automobile or electric automobile. The control may be based in part upon real-time fast Fourier transform analysis of load current, permitting real-time adjustment of control coefficients. In this way, it is possible to minimize the occurrence of the capacitor being fully charged at a time when it would be desired to be able to absorb high current, for example from regenerative braking. Likewise it is possible to minimize the occurrence of the capacitor being nearly discharged at a time when it would be desirable to have boost power available. A result is that even a relatively small ultracapacitor (having perhaps one two-hundredth the energy storage capacity of the battery) can permit greatly reducing waste heat dissipated in the battery, and can reduce otherwise unnecessary cycling of current into and out of the battery. This can extend battery life and battery performance.

Claims

1. A method for use with an energy storage system connected with a variable load, the load at some times drawing power from the energy storage system and at other times regenerating power to be stored within the energy storage system, the power draw being greater at some times and lesser at other times, the regenerated power to be stored being greater at some times and lesser at other times, the energy storage system comprising a storage battery and an ultracapacitor, the method comprising the steps of:

monitoring the state-of-charge (SOC) of the ultracapacitor;

dynamically establishing a set point toward which the SOC is configured to be driven; and

adjusting the dynamic set point as a function of sensed load currents, wherein the sensed load currents are sensed between the storage system and the load, and

wherein the dynamic establishment of the set point is a function of an average of the lowest three frequencies obtained by a fast Fourier transform of the sensed load currents.

2. The method of claim 1, further comprising driving the SOC of the capacitor toward the set point, wherein the driving is carried out so as to allocate more current to charging of the capacitor if the SOC is approaching zero, even if current is also being supplied by the battery to the load, and wherein the driving is carried out so as to allocate less current to charging of the capacitor if the SOC is approaching 100%, even if current is also being supplied by the load to the battery.

3. The method of claim 1, wherein monitoring the SOC of the ultracapacitor comprises sensing an ultracapacitor voltage U_c and calculating the SOC based upon the sensed ultracapacitor voltage U_c and a maximum permitted ultracapacitor voltage U_mx of the ultracapacitor.

4. The method of claim 1, wherein adjusting the dynamic set point comprises scheduling feedback gains of a control loop configured to adjust the amount of current flowing between the ultracapacitor and the battery.

5. The method of claim 1, further comprising adjusting the amount of current flowing between the ultracapacitor and the battery based upon the dynamic set point.

6. The method of claim 5, wherein adjusting the amount of current flowing between the ultracapacitor and the battery comprises adjusting the amount of current flowing between the ultracapacitor and the battery when the sensed load current is approximately zero.

7. The method of claim 1, further comprising resetting the set-point upon occurrence of a sensed event indicative of a change of operator of the system.

8. The method of claim 7 wherein the system is part of a motor vehicle with a seat having an adjustable position, the sensed event comprising adjustment of the position of the seat.

9. The method of claim 7 wherein the system is part of a motor vehicle with a mirror having an adjustable position, the sensed event comprising adjustment of the position of the minor.

10. An energy storage system for connection with a variable load, the load at some times drawing power from the energy storage system and at other times regenerating power to be stored within the energy storage system, the power draw being greater at some times and lesser at other times, the regenerated power to be stored being greater at some times and lesser at other times, the energy storage system comprising:

a storage battery;

an ultracapacitor having a state of charge (SOC);

a power converter in series with the ultracapacitor;

the ultracapacitor and power converter together in parallel with the battery and in turn disposed for connection with the variable load;

a load current sensor configured to sense a load current between the storage system and the load; and

a controller connected with the load sensor and one or more SOC sensors configured to determine the SOC of the ultracapacitor;

wherein the controller is configured to be responsive to one or more of the sensed load currents for dynamically establishing a set point toward which the SOC is configured to be driven, and adjusting the dynamic set point as a function of the sensed load current, and

wherein the controller is configured to dynamically establish the set point as a function of an average of the lowest three frequencies obtained by a fast Fourier transform of a plurality of the sensed load currents.

11. The energy storage system of claim 10 wherein the controller is configured to drive the SOC of the ultracapacitor such that more current is allocated to charging the capacitor if the SOC is approaching zero, even if current is also being supplied by the battery to the load, and wherein the controller is configured to drive the SOC of the ultracapacitor such that less current is allocated to charging the capacitor if the SOC is approaching 100%, even if current is also being supplied by the load to the battery.

12. The energy storage system of claim 10, further comprising a voltage sensor configured to sense an ultracapacitor voltage U_c, wherein the controller is configured to calculate the SOC based upon the sensed ultracapacitor voltage U_c and a maximum permitted ultracapacitor voltage U_mx of the ultracapacitor.

13. The energy storage system of claim 10, wherein the controller is configured to schedule feedback gains of the power converter based upon the dynamic set point to adjust the amount of current flowing between the ultracapacitor and the battery.

14. The energy storage system of claim 10, wherein the controller is configured to adjust the amount of current flowing between the ultracapacitor and the battery based upon the dynamic set point.

15. The energy storage system of claim 14, wherein the controller is configured to adjust the amount of current flowing between the ultracapacitor and the battery when the sensed load is approximately zero.

16. The energy storage system of claim 10 wherein the controller is configured to reset the set-point in response to a sensed event indicative of a change of operator of the system.

17. The energy storage system of claim 16 wherein the system is part of a motor vehicle with a seat having an adjustable position, wherein the sensed event comprises adjustment of the position of the seat.

18. The energy storage system of claim 16 wherein the system is part of a motor vehicle with a minor having an adjustable position, wherein the sensed event comprises adjustment of the position of the minor.