System and method for balancing charge between battery cells

• US 9,641,004 B2
• Filed: 04/17/2012
• Issued: 05/02/2017
• Est. Priority Date: 04/20/2011
• Status: Active Grant

• Current Assignee: A123 Systems Incorporated
• Original Assignee: A123 Systems Incorporated
• Inventors: Floros, John H., Firehammer, Paul W.
• Primary Examiner(s): Tso, Edward
• Assistant Examiner(s): Omar, Ahmed
• Application Number:
  US14/112,102
• Publication Number:
  US 20140042980A1
• Time in Patent Office: 1,841 Days
• Field of Search: 320116
• CPC Class Codes: H01M 10/441 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: H02J 7/0014 Circuits for equalisation of charge between batteries
• CPC Class Codes: H02J 7/0016 using shunting, discharge or bypass circuits
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

Systems and methods for balancing charge of battery cells of a battery pack are disclosed. In one example, battery cell balancing may be improved by balancing battery cells of a battery cell stack simultaneously. The system and method may be particularly useful battery packs that may be constructed with battery cell stacks that vary in a number of series battery cells.

Claims

1. A method for balancing charge of a battery pack, the battery pack comprising a plurality of battery cell stacks, comprising:

balancing charge of at least one battery cell of the battery pack during a second battery cell charge balancing cycle responsive to at least one battery cell charge sample from a plurality of battery cells sampled during a first battery cell charge balancing cycle; and

balancing charge of the at least one battery cell of the battery pack during the second battery cell charge balancing cycle responsive to the plurality of battery cells sampled simultaneously during the second battery cell charge balancing cycle.

2. The method of claim 1, where the plurality of battery cell stacks of the battery pack are simultaneously sampled during the first battery cell charge balancing cycle, where balancing charge of the at least one battery cell includes passively discharging the at least one battery cell, and where balancing charge of the at least one battery cell is deactivated during simultaneously sampling of a plurality of battery cell voltages.

3. The method of claim 2, further comprising balancing charge of at least a second battery cell after simultaneously sampling the plurality of battery cell voltages of the battery pack during the first battery cell charge balancing cycle and before simultaneously sampling the plurality of battery cell voltages of the battery pack during the second battery cell charge balancing cycle.

4. The method of claim 1, where voltages of the plurality of battery cell stacks of the battery pack are simultaneously sampled during the first battery cell charge balancing cycle.

5. The method of claim 1, where the battery pack is comprised of the plurality of battery cell stacks and where at least two of the plurality of battery cell stacks have different numbers of battery cells electrically coupled in series.

6. The method of claim 5, where initiating of battery cell charge balancing of the plurality of battery cell stacks occurs substantially simultaneously.

7. The method of claim 1, where balancing charge of at least one battery cell includes actively charging or discharging the at least one battery cell via a charge storing device.

8. A method for balancing charge of a battery pack, the battery pack comprising a plurality of battery cell stacks, comprising:

simultaneously sampling a plurality of battery cells of a first battery cell stack and a plurality of battery cells of a second battery cell stack, the second battery cell stack including a different number of battery cells electrically connected in series than the first battery cell stack; and

simultaneously balancing charge of at least one battery cell of the first battery cell stack and at least one battery cell of the second battery cell stack after simultaneously sampling the plurality of battery cells from the first battery cell stack and the plurality of battery cells of the second battery cell stack.

9. The method of claim 8, further comprising simultaneously sampling the plurality of battery cells of the first battery cell stack and the plurality of battery cells of the second battery cell stack responsive to an instruction from a battery control module.

10. The method of claim 8, where charge of the at least one battery cell of the first battery cell stack and the at least one battery cell of the second battery cell stack is charge balanced according to battery charge sampled during a previous battery cell charge balancing cycle that occurred before the simultaneous sampling of the plurality of battery cells of the first battery cell stack and the plurality of battery cells of the second battery cell stack.

11. The method of claim 10, further comprising balancing charge of the at least one battery cell of the first battery cell stack and the at least one battery cell of the second battery cell stack in response to battery charge sampled during the simultaneous sampling of the plurality of battery cells of the first battery cell stack and the plurality of battery cells of the second battery cell stack.

12. The method of claim 8, where the plurality of battery cells of the first battery cell stack and the plurality of battery cells of the second battery cell stack are passively charge balanced via load resistors.

13. The method of claim 8, further comprising independently processing data from the simultaneous sampling of the plurality of battery cells of the first battery cell stack and the simultaneous sampling of the plurality of battery cells of the second battery cell stack.

14. A system for balancing charge of a battery pack, comprising:

a first battery cell stack comprised of a first actual total number of battery cells;

a first monitoring and charge balancing controller electrically coupled to the first battery cell stack, the first monitoring and charge balancing controller including instructions for monitoring and charge balancing battery cells in the first battery cell stack;

a second battery cell stack comprised of a second actual total number of battery cells different from the first actual total number of battery cells;

a second monitoring and charge balancing controller electrically coupled to the second battery cell stack, the second monitoring and charge balancing controller including instructions for monitoring and charge balancing battery cells in the second battery cell stack, the second monitoring and charge balancing controller including further instructions for starting charge balancing of battery cells in the second battery cell stack substantially simultaneously with starting charge balancing of battery cells in the first battery cell stack; and

a battery control module including a battery controller, the battery controller in electrical communication with the first and second monitoring and charge balancing controllers, where the battery cells in the first battery cell stack include battery cells electrically coupled in parallel, where the battery cells in second battery cell stack include battery cells electrically coupled in parallel, where the battery controller includes instructions to initiate substantially simultaneous sampling of battery cells in the first and second battery cell stacks, and the battery controller including further instructions for balancing charge of the battery cells of the first battery cell stack during a second battery cell charge balancing cycle responsive to at least one battery cell charge sample from the battery cells of the first battery cell stack sampled during a first battery cell charge balancing cycle.

15. The system of claim 14, where the first monitoring and charge balancing controller includes instructions for processing charge balancing data for the first actual total number of battery cells and the second monitoring and charge balancing controller includes instructions for processing charge balancing data for the second actual total number of battery cells.

16. The system of claim 14, further comprising passive charge balancing circuitry electrically coupled to the first monitoring and charge balancing controller, and passive charge balancing circuitry electrically coupled to the second monitoring and charge balancing controller.

17. The system of claim 14, further comprising active charge balancing circuitry electrically coupled to the first monitoring and charge balancing controller, and active charge balancing circuitry electrically coupled to the second monitoring and charge balancing controller.