Bidirectional DC converter-based battery simulator

• US 9,404,977 B2
• Filed: 04/17/2014
• Issued: 08/02/2016
• Est. Priority Date: 04/17/2014
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Tran, Tuyen Q., Tabatowski-Bush, Ben A.
• Primary Examiner(s): WILLIAMS, ARUN C
• Application Number:
  US14/255,381
• Publication Number:
  US 20150301120A1
• Time in Patent Office: 838 Days
• Field of Search: 324/434
• US Class Current: 1/1
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 2270/20 Inrush current reduction, i.e. avoiding high currents when connecting the battery
• CPC Class Codes: B60L 3/0084 relating to control modules
• CPC Class Codes: G01R 31/2848 using simulation
• CPC Class Codes: G01R 31/367 Software therefor, e.g. for battery testing using modelling or look-up tables
• CPC Class Codes: G01R 31/3828 using current integration
• 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: H01M 10/4207 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 2010/4271 Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing
• 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 10/72 Electric energy management in electromobility

Abstract

A battery simulator is configured to provide large energy pulses for hot plug testing while maintaining the ability to quickly respond during random order testing. A simulator can comprise a plurality of cell simulators “cellsims” coupled to a DC power supply. Each cellsim can include a bidirectional DC converter, a bulk capacitor on the primary side of the converter, and a switchable discharge capacitor on the secondary side of the converter. The bidirectional DC converter enables the simulator to cooperate with a battery control module (BCM) to perform active cell balancing. Energy received from the BCM can be stored at the bulk capacitor. The discharge capacitor can be coupled to an output link to provide a high energy pulse to the BCM to simulate hot plug conditions, and can be decoupled from the link during random order testing. Output link voltage and current can be monitored for fault detection.

Claims

1. A system, comprising:

a battery control module (BCM) configured to monitor charge of one or more cells of an electrified vehicle (EV) traction battery;

a simulator, configured for bidirectional energy exchange with said BCM, configured to simulate operation of said traction battery;

wherein said simulator comprises a bidirectional DC/DC converter; and

wherein said simulator comprises a discharge capacitor configured to store energy received from said bidirectional DC/DC converter and release said stored energy to said BCM during a hot plug test.

2. The system of claim 1, further comprising a bulk storage capacitor.

3. The system of claim 1, wherein said BCM and said simulator are configured to perform active cell balancing.

4. A battery simulator, comprising:

a power supply;

one or more cell simulators (cellsims) coupled to said power supply, each said cellsim configured to simulate a cell of an electrified vehicle (EV) traction battery;

wherein said cellsim comprises a bidirectional DC/DC converter configured for bidirectional energy exchange with a battery control module (BCM) configured to monitor said traction battery charge, and a discharge capacitor configured to store energy received from said converter and controllably release said stored energy to a link coupling said cellsim and said BCM.

5. The battery simulator of claim 4, further comprising at least one cellsim control module (CCM), each said CCM configured to control operation of at least one of said cellsims.

6. The battery simulator of claim 5, wherein said CCM is configured to monitor current between said cellsim and said BCM.

7. The battery simulator of claim 4, configured to cooperate with said BCM to perform active cell balancing.

8. The battery simulator of claim 4, wherein said active cell balancing comprises a donor cellsim providing energy to said BCM, and a receiver cellsim receiving said energy from said BCM.

9. The battery simulator of claim 4, configured to store energy received from said BCM at a bulk capacitor at said cellsim.

10. The battery simulator of claim 4, wherein said cellsim comprises a switch disposed between said discharge capacitor and said converter.

17. The battery simulator of claim 4, wherein a bulk capacitor is disposted at a first side of said converter, and said discharge capacitor is disposed at a second side of said converter.

11. A battery simulator, comprising:

a power supply; and

at least one cell simulator (cellsim), said cellsim configured to simulate an energy cell of an electrified vehicle (EV) traction battery, said cellsim comprising a discharge capacitor switchably controlled to provide energy to a battery control module (BCM) for said traction battery; and

wherein said discharge capacitor is coupled to a link between said cellsim and said BCM to hot plug test said BCM, and decoupled from said link to simulate an electric vehicle drive mode condition of said traction battery.

12. The battery simulator of claim 11, further comprising at least one cellsim control module (CCM) configured to control operation of at least one said cellsim.

13. The battery simulator of claim 11, wherein said cellsim comprises a DC/DC converter configured for bidirectional energy transfer with said BCM.

14. The battery simulator of claim 11, wherein said discharge capacitor is switchably coupled to a DC/DC converter.

15. The battery simulator of claim 11, wherein said discharge capacitor is switchably coupled to a voltage bus configured to couple said DC/DC converter to said BCM.

16. The battery simulator of claim 11 , wherein said simulator is configured to monitor said cellsim output and provide a fault response when said cellsim output indicates a fault condition.