Semi-active partial parallel battery architecture for an automotive vehicle systems and methods

• US 9,969,292 B2
• Filed: 11/11/2015
• Issued: 05/15/2018
• Est. Priority Date: 11/14/2014
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Thieme, Bryan L., Le, Daniel B.
• Primary Examiner(s): Hernandez, William
• Application Number:
  US14/938,664
• Publication Number:
  US 20160137092A1
• Time in Patent Office: 916 Days
• Field of Search: 307 101, 307 106
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60L 1/00 Supplying electric power to auxiliary equipment of vehicles circuit arrangements for charging batteries H02J7/00
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2260/26 Transition between different drive modes
• CPC Class Codes: B60L 50/10 using propulsion power supplied by engine-driven generators, e.g. generators driven by combustion engines
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 58/12 responding to state of charge [SoC]
• CPC Class Codes: B60L 58/13 Maintaining the SoC within a determined range
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: B60L 7/14 for vehicles propelled by ac motors
• CPC Class Codes: B60R 16/03 for supply of electrical power to vehicle subsystems or for circuit arrangements for charging batteries H02J7/00
• CPC Class Codes: B60R 16/033 characterised by the use of electrical cells or batteries for propulsion puposes B60K1/04; supplying batteries to, or removing batteries from, vehicles B60S5/06; testing of charge state G01R31/36
• CPC Class Codes: B60W 10/06 including control of combustion engines
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/26 for electrical energy, e.g. batteries or capacitors
• CPC Class Codes: B60W 20/13 in order to stay within battery power input or output limits; in order to prevent overcharging or battery depletion
• CPC Class Codes: B60W 20/14 in conjunction with braking regeneration
• CPC Class Codes: B60W 2510/244 Charge state
• CPC Class Codes: B60W 2540/06 : Ignition switch
• CPC Class Codes: B60W 2710/248 : Current for loading or unloading
• CPC Class Codes: B60W 30/18127 : Regenerative braking
• CPC Class Codes: B60W 30/192 : Mitigating problems related to power-up or power-down of the driveline, e.g. start-up of a cold engine
• CPC Class Codes: F02N 11/0866 : comprising several power sources, e.g. battery and capacitor or two batteries
• 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 10/06 : Lead-acid accumulators semi-lead accumulators H01M10/20
• CPC Class Codes: H01M 10/441 : for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 16/00 : Structural combinations of different types of electrochemical generators
• 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 10/70 : 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

Abstract

An automotive battery system that includes a lead-acid battery electrically coupled to a first bus, in which the lead-acid battery supplies electrical power to a starter via the first bus to cold crank an internal combustion engine of a vehicle; a lithium-ion battery electrically coupled to a second bus, in which the lithium-ion battery captures and stores electrical energy generated by a regenerative braking system when the vehicle brakes and supplies electrical power to the second bus using the electrical energy captured from the regenerative braking system such that a first portion of the second electrical power is supplied to an electrical system; and a DC/DC converter electrically coupled between the first bus and the second bus, in which the DC/DC converter controls supply of a second portion of the second electrical power to charge the lead-acid battery.

Claims

1. An automotive battery system, comprising:

a lead-acid battery electrically coupled to a first bus, wherein the lead-acid battery is configured to supply first electrical power to a starter via the first bus to cold crank an internal combustion engine of a vehicle;

a lithium-ion battery electrically coupled to a second bus, wherein the lithium-ion battery is configured to;

capture and store electrical energy generated by a regenerative braking system when the vehicle brakes; and

supply second electrical power to the second bus using the electrical energy captured from the regenerative braking system; and

a DC/DC converter electrically coupled between the first bus and the second bus, wherein the DC/DC converter is configured to control division of the second electrical power into;

a first portion of the second electrical power supplied to an electrical system via the second bus; and

a second portion of the second electrical power supplied to the first bus-to charge the lead-acid battery.

2. The automotive battery system of claim 1, wherein:

the vehicle is configured to disable the internal combustion engine when idle and key on; and

the automotive battery system is configured to subsequently supply third electrical power to the starter to warm crank the internal combustion engine, wherein;

the lead-acid battery is configured to supply a first portion of the third electrical power and the lithium-ion battery is configured to supply a second portion of the third electrical power when a state of charge of the lithium-ion battery is greater than a first threshold or a state of charge of the lead-acid battery is less than a second threshold; and

the lead-acid battery is configured to supply the third electrical power by itself when the state of charge of the lead-acid battery is not less than the second threshold.

3. The automotive battery system of claim 1, wherein, when the vehicle is key off and a state of charge of the lead-acid battery is less than a threshold:

the lithium-ion battery is configured to supply third electrical power to the second bus; and

the DC/DC converter is configured to control division of the third electrical power into;

a first portion of the third electrical power supplied to the electrical system via the second bus to power key off loads; and

a second portion of the third electrical power supplied to the first bus to charge the lead-acid battery.

4. The automotive battery system of claim 1, comprising a bypass mechanical switch configured to be:

open when the vehicle is key on; and

closed when the vehicle is key off and a state of charge of the lead-acid battery is not less than a threshold to bypass the DC/DC converter, wherein the lead-acid battery is configured to supply third electrical power through the bypass mechanical switch to the electrical system when the bypass mechanical switch is closed.

5. The automotive battery system of claim 1, wherein:

the starter and the lead-acid battery are configured to operate with twelve volt electrical power;

the electrical system, the regenerative braking system, and the lithium-ion battery are configured to operate with forty-eight volt electrical power; and

the DC/DC converter is configured to;

convert forty-eight volt electrical power from the second bus to twelve volt electrical power output to the first bus to charge the lead-acid battery; and

convert twelve volt electrical power from the first bus to forty-eight volt electrical power output to the second bus when the vehicle is key off.

6. The automotive battery system of claim 1, wherein the lead-acid battery is configured to supply the first electrical power to the starter when the vehicle transitions from key off to key on.

7. The automotive battery system of claim 1, wherein the DC/DC converter is configured to:

disconnect the second bus from the first bus during regenerative braking such that the electrical energy generated by the regenerative braking system is not captured by the lead-acid battery; and

disconnect the first bus from the second bus when the internal combustion engine is cold cranked such that the lithium-ion battery does not supply electrical power to the starter.

8. The automotive battery system of claim 1, wherein the DC/DC converter is configured to control charging of the lead-acid battery by controlling current flow from the second bus to the first bus based at least in part on charge acceptance rate limit of the lead-acid battery, power consumption by the electrical system, or both.

9. The automotive battery system of claim 1, wherein:

the lead-acid battery is configured to be electrically coupled in parallel with the starter; and

the lithium-ion battery is configured to be electrically coupled in parallel with the regenerative braking system and the electrical system.

10. The automotive battery system of claim 1, wherein:

the lead-acid battery is configured to operate at lower operating temperatures, is less affected by deep discharging, or both compared to the lithium-ion battery; and

the lithium-ion battery comprises a higher coulombic efficiency, a higher charge acceptance rate limit, or both compared to the lead-acid battery.

11. The automotive battery system of claim 1, wherein the lithium-ion battery comprises a lithium nickel manganese cobalt oxide battery, a lithium-titanate/lithium nickel manganese cobalt oxide battery, a lithium-titanate/lithium manganese oxide battery, or a lithium iron phosphate battery.

12. A method for operating a battery system, comprising:

cold cranking, using a starter, an internal combustion engine when a vehicle is transitioned from key off to key on, wherein a first battery of the battery system supplies first electrical power to the starter to cold crank the internal combustion engine;

converting, using a regenerative braking system, mechanical energy from motion of the vehicle into electrical energy;

capturing, using a second battery of the battery system, the electrical energy generated by the regenerative braking system;

outputting second electrical power from the second battery using the electrical energy generated by the regenerative braking system; and

controlling dividing, using a DC/DC converter, the second electrical power into;

a first portion of the second electrical power supplied to an electrical system of the vehicle; and

a second portion of the second electrical power used to charge the first battery.

13. The method of claim 12, comprising:

disabling the internal combustion engine when the vehicle is key on and idling;

warm cranking, using the starter, the internal combustion engine when propulsion is desired, wherein the battery system supplies third electrical power to the starter to warm crank the internal combustion engine, wherein;

the first battery supplies the third electrical power by itself when a state of charge of the first battery is greater than a threshold; and

the first battery supplies a first portion of the third electrical power and the second battery supplies a second portion of the third electrical power when the state of charge of the first battery is not greater than the threshold.

14. The method of claim 12, comprising outputting third electrical power from the second battery when the vehicle is key off, wherein:

the third electrical power is used to power the electrical system when a state of charge of the first battery is greater than a threshold;

a first portion of the third electrical power is used to power the electrical system; and

a second portion of the third electrical power is used to charge the first battery when the state of charge of the first battery is not greater than the threshold.

15. The method of claim 12, wherein dividing the second electrical power comprises controlling a magnitude of current flowing from the second battery, through the DC/DC converter, and into the first battery.

16. The method of claim 12, wherein converting the mechanical energy into the electrical energy comprises using the motion of the vehicle to actuate a generator such that third electrical power is output to the second battery.

17. The method of claim 12, wherein the first battery comprises a lead-acid battery and the second battery comprises a lithium-ion battery.

18. A tangible, non-transitory, computer-readable medium that stores instructions executable by at least one processor in a vehicle, wherein the instructions comprise instructions to:

instruct, using the at least one processor, a battery system of the vehicle to disconnect a first battery from a starter of the vehicle to enable a second battery to supply first electrical power to the starter by itself to cold crank an internal combustion engine when the vehicle transitions from key off to key on;

determine, using the at least one processor, whether a state of charge of the first battery is greater than a first threshold;

instruct, using the at least one processor, an alternator of the vehicle to convert first mechanical energy from the internal combustion engine into first electrical energy when the state of charge of the first battery is not greater than the first threshold such that at least a portion of second electrical power output by the alternator is used to charge the first battery above the first threshold; and

instruct, using the at least one processor, the battery system to control division of third electrical power output from the first battery between a first portion used to charge the second battery and a second portion used to power an electrical system of the vehicle when the state of charge of the first battery is greater than the first threshold.

19. The computer-readable medium of claim 18, comprising instructions to:

determine, using the at least one processor, when the vehicle is braking; and

instruct, using the at least one processor, a regenerative braking system to convert second mechanical energy from motion of the vehicle into second electrical energy when the vehicle is braking such that the second battery captures and stores at least a portion of the second electrical energy.

20. The computer-readable medium of claim 18, wherein:

the instructions to instruct the battery system to disconnect the first battery comprise instructions to instruct a DC/DC converter in the battery system to disconnect by ceasing toggling of an internal switch; and

the instructions to instruct the battery system to control division of the third electrical power comprise instructions to instruct the DC/DC converter to control current flow from the first battery, through the DC/DC converter, and into the second battery by controlling toggling rate of the internal switch based at least in part on charge acceptance rate limit of the second battery, power consumption by the electrical system, or both.

21. The computer-readable medium of claim 18, comprising instructions to:

determine, using the at least one processor, when the vehicle is key off and idle;

instruct, using the at least one processor, the internal combustion engine to disable when the vehicle is key off and idle;

determine, using the at least one processor, when propulsion of the vehicle is subsequently desired;

determine, using the at least one processor, whether a state of charge of the second battery is less than a second threshold when propulsion is subsequently desired;

instruct, using the at least one processor, the battery system to disconnect the first battery from the starter to enable the second battery to supply fourth electrical power to the starter by itself to warm crank the internal combustion engine when the state of charge of the second battery is not less than the second threshold; and

instruct, using the at least one processor, the battery system to connect the first battery and the second battery to the starter to enable the first battery and the second battery to supply the fourth electrical power to the starter to warm crank the internal combustion engine when the state of charge of the second battery is less than the second threshold.

22. The computer-readable medium of claim 18, comprising instructions to, when the vehicle is key off:

determine, using the at least one processor, a state of charge of the second battery;

instruct, using the at least one processor, a bypass switch to close when the state of charge of the second battery is greater than a second threshold such that the second battery supplies fourth electrical power used to power key off loads in the electrical system; and

instruct, using the at least one processor, the bypass switch to remain open and a DC/DC converter in the battery system to control division of fifth electrical power output from the first battery between a first portion used to power the key off loads and a second portion used to charge the second battery when the state of charge of the second battery is less than the second threshold.

23. The computer-readable medium of claim 18, wherein the first battery comprises a lithium-ion battery and the second battery comprises a lead-acid battery.