Refuelable battery powered electric vehicle

• US 9,381,822 B2
• Filed: 04/28/2014
• Issued: 07/05/2016
• Est. Priority Date: 02/09/2006
• Status: Active Grant

• Current Assignee: Karl F. Scheucher
• Original Assignee: Karl F. Scheucher
• Inventors: Scheucher, Karl F.
• Primary Examiner(s): Tso, Edward
• Assistant Examiner(s): Piggush, Aaron
• Application Number:
  US14/264,041
• Publication Number:
  US 20140312845A1
• Time in Patent Office: 799 Days
• Field of Search: 320/104, 320/125, 320/132, 320/134, 320/163, 903/903, 903/907
• US Class Current: 1/1
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 2001/0455 Removal or replacement of the energy storages
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 2240/525 Temperature of converter or components thereof
• CPC Class Codes: B60L 2270/34 of parts
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 53/11 DC charging controlled by the charging station, e.g. mode 4
• CPC Class Codes: B60L 53/20 characterised by converters located in the vehicle
• CPC Class Codes: B60L 53/305 Communication interfaces
• CPC Class Codes: B60L 53/80 Exchanging energy storage elements, e.g. removable batteries
• CPC Class Codes: B60L 58/12 responding to state of charge [SoC]
• CPC Class Codes: B60L 8/00 Electric propulsion with power supply from forces of nature, e.g. sun or wind
• CPC Class Codes: B60L 8/003 Converting light into electric energy, e.g. by using photo-voltaic systems
• CPC Class Codes: B60W 2050/146 Display means
• CPC Class Codes: B60W 2540/215 Selection or confirmation of options
• CPC Class Codes: B60W 50/082 Selecting or switching between different modes of propelling
• CPC Class Codes: B60W 50/085 Changing the parameters of the control units, e.g. changing limit values, working points by control input
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• 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 10/613 : Cooling or keeping cold
• CPC Class Codes: H01M 10/625 : Vehicles
• CPC Class Codes: H01M 10/643 : Cylindrical cells
• CPC Class Codes: H01M 10/6557 : arranged between the cells
• CPC Class Codes: H01M 10/667 : the system being an electronic component, e.g. a CPU, an inverter or a capacitor
• CPC Class Codes: H01M 50/204 : Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H02J 2310/48 : for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 3/322 : the battery being on-board an electric or hybrid vehicle, e.g. vehicle to grid arrangements [V2G], power aggregation, use of the battery for network load balancing, coordinated or cooperative battery charging
• CPC Class Codes: H02J 7/0013 : acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0045 : concerning the insertion or the connection of the batteries
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02P 90/60 : Electric or hybrid propulsion means for production processes
• 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 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y02T 90/12 : Electric charging stations
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y02T 90/167 : Systems integrating technologies related to power network operation and communication or information technologies for supporting the interoperability of electric or hybrid vehicles, i.e. smartgrids as interface for battery charging of electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: Y04S 30/14 : Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing

Abstract

The electrical vehicle energy storage system permits the electric refueling of the electric vehicle just like an automobile would be refueled with gasoline at a gas station. Circuitry on board the vehicle accessible by the electric refueling station enables the determination of the energy content of the battery module or modules returned to the electric refueling station and the owner of the vehicle is given credit for the energy remaining in the battery module or modules which have been exchanged. Selective refueling may take place for given battery modules by removing them from the battery system and charging them at home, office or factory. A process for operating an electric vehicle is also disclosed and claimed.

Claims

1. A process for operating an electric vehicle comprising the steps of:

measuring the state of charge of each of a plurality of battery modules while said battery modules are on-board said electric vehicle, each one of said plurality of battery modules being in parallel with one another;

measuring the power demand of an on-board electrical drive system of said electric vehicle;

selectively coupling the most highly charged battery modules to said on-board electrical drive system more often than lesser charged battery modules when said on-board electrical drive system is under load requiring power from said plurality of battery modules;

selectively coupling the least highly charged battery modules to said on-board electrical drive system more often than more highly charged battery modules when said on-board electrical drive system is sourcing power under conditions from an on-board regenerative power source;

maintaining a duty-cycle of charging and discharging of battery modules within specified limits of each particular battery module, said specified limits of each battery module include a predefined low state of charge and a predefined high state of charge for each of said plurality of battery modules; and

, converging each of said battery modules toward an equal state of charge by said selective coupling.

2. A process for operating an electric vehicle as claimed in claim 1 further comprising the steps of:

measuring voltage, current, .and temperature of each of said plurality of battery modules;

and calculating, with a microcontroller, using said voltage, current, and temperature measurements, an absolute charge capacity of each of said plurality of battery modules.

3. A process for operating an electric vehicle as claimed in claim 2 further comprising the steps of:

connecting each of said plurality of battery modules to said on-board electrical system until each of said battery modules reaches a predefined low state of charge;

disconnecting each of said plurality of battery modules from said on-board electrical system once it has reached said predefined low state of charge;

connecting each of said plurality of battery modules that were disconnected from said onboard electrical system once it has reached said predefined low state of charge to a charge bus;

disconnecting each of said plurality of battery modules from said charge bus when each of said battery modules reach a predefined high state of charge; and

reconnecting each of said plurality of battery modules that has reached a predefined high state of charge to said on-board electrical system.

4. A process for operating an electric vehicle as claimed in claim 1 wherein said predefined high state of charge and said predefined low state of charge are calculated by a microprocessor based on known battery chemistry, cell size, nominal voltage and a set of measured values including operating voltage of each of said plurality of battery modules, including operating current of each of said plurality of battery modules, and operating temperature of each of said plurality of battery modules.

5. A process for operating an electric vehicle as claimed in claim 4 further comprising the steps of:

protecting each of said plurality of battery modules with a respective battery interface circuit, said battery interface circuit includes a plurality of switches and diodes.

6. A process for operating an electric vehicle comprising the steps of:

utilizing a controller to measure the state of charge of each of a plurality of battery modules using respective battery module interface circuits, each one of said plurality of battery modules being in parallel with one another;

utilizing said controller and a power interface circuit to measure the power demand of an electric drive system;

utilizing said controller, said respective battery module interface circuits, and said state of charge measurements to selectively couple more highly charged battery modules to said electric drive system more often than less charged battery modules when said electric drive system is under load requiring power;

utilizing said controller, said respective battery module interface circuits, and said state of charge measurements to selectively couple less charged battery modules to said electric drive system more often than more highly charged battery modules when said electric drive system is sourcing power under conditions of regenerative braking or other electrical generation; and

, utilizing said controller, said respective battery module interface circuits, and said state of charge measurements to determine duty cycles of charging and discharging each of said plurality of battery modules maintaining each below a particular high state of charge, maintaining each above a particular low state of charge, and converging each toward a particular preferred state of charge.

7. A process for operating an electric vehicle as claimed in claim 6 wherein said high state of charge, said low state of charge, and said preferred state of charge are calculated by said controller based upon battery chemistry, nominal battery capacity, nominal battery voltage, and a set of measured values including:

operating voltage of each of said plurality of battery modules, operating current of each of said plurality of battery modules, and operating temperature of each of said plurality of battery modules.

8. A process for operating an electric vehicle as claimed in claim 6 wherein said high state of charge, said low state of charge, and said preferred state of charge are calculated by said controller based upon battery age and battery state of health.

9. A process for operating an electric vehicle comprising the steps of:

measuring state of charge of each of a plurality of battery modules, each of said plurality of battery modules includes specified limits for charging and discharging duty cycles, respectively, each one of said plurality of battery modules being in parallel with one another;

measuring power demand of the electric drive system of said electric vehicle;

selecting a first group of battery modules from said plurality of battery modules;

selecting a second group of battery modules from said plurality of battery modules;

selectively coupling, on a battery module by battery module basis, utilizing a battery interface circuit associated with and dedicated to each said battery module and a microprocessor, one or more battery modules from said first group of battery modules to said electrical drive system more often than battery modules from said second group of battery modules when said drive system is under load requiring power from said battery modules, said battery interface circuit includes switches interconnecting said battery modules of said first group of battery modules to said electrical drive system and said battery interface circuit includes diodes or equivalent current steering circuit components permitting current flow from said battery modules of said first group of battery modules to said electric drive system but not permitting current flow from said electric drive system to said battery modules of said first group of battery modules, said microprocessor controlling said switches of said battery interface circuit enabling said selective coupling of said battery modules of said first group of battery modules to said electric drive system;

selectively coupling, on a battery module by battery module basis, utilizing said battery interface circuit associated with and dedicated to each said battery module and a microprocessor, one or more of said battery modules of said second group of battery modules to said electric drive system more often than said battery modules of said first group of battery modules when said drive system is sourcing power under conditions of regenerative braking, said battery interface circuit includes switches interconnecting said battery modules of said second group of battery modules to said electric drive system when said drive system is sourcing power under conditions of regenerative braking, said battery interface circuit includes diodes or equivalent current steering circuit components permitting current flow from said electric drive system to said battery modules of said second group of battery modules but not permitting current flow from said battery modules of said second group of battery modules to said electric drive system, said microprocessor controlling said switches of said battery interface circuit enabling said selective coupling of said battery modules of said second group of battery modules to said electric drive system during conditions of regenerative braking;

maintaining said charging and discharging duty-cycles of each of said battery modules within said specified limits of each said battery module; and

,

facilitating, by said selective coupling of said battery modules, convergence of said battery modules of said first group of battery modules to a first state of charge and convergence of said battery modules of said second group of battery modules to a second state of charge.