Battery energy storage system and control system and applications thereof

• US 10,536,007 B2
• Filed: 12/18/2017
• Issued: 01/14/2020
• Est. Priority Date: 03/05/2011
• Status: Active Grant

• Current Assignee: Powin Corporation (Powin Energy Corporation)
• Original Assignee: Powin Energy Corporation
• Inventors: Beaston, Virgil Lee, Tyrrell, Robert Nelson
• Primary Examiner(s): Lin, Sun J
• Application Number:
  US15/845,598
• Publication Number:
  US 20180123357A1
• Time in Patent Office: 757 Days
• Field of Search: 320103
• 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 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• 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 10/486 for measuring temperature
• 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 2220/10 Batteries in stationary systems, e.g. emergency power source in plant
• CPC Class Codes: H01M 50/204 Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H02J 2300/24 of photovoltaic origin
• CPC Class Codes: H02J 2300/28 The renewable source being wind energy wind motors F03D
• CPC Class Codes: H02J 3/381 Dispersed generators
• CPC Class Codes: H02J 3/388 Islanding, i.e. disconnection of local power supply from the network
• CPC Class Codes: H02J 7/0019 using switched or multiplexed charge circuits
• CPC Class Codes: H02J 7/0025 Sequential battery discharge in systems with a plurality of batteries
• CPC Class Codes: H02J 7/0048 Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/005 Detection of state of health [SOH]
• CPC Class Codes: Y02E 10/56 Power conversion systems, e.g. maximum power point trackers
• CPC Class Codes: Y02E 10/76 Power conversion electric or electronic aspects
• CPC Class Codes: Y02E 40/10 Flexible AC transmission systems [FACTS]
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries

Abstract

Disclosed herein are embodiments of an electrical energy storage unit, a control system, and applications thereof. In an embodiment, the electrical energy storage unit (which may also be referred to as a battery energy storage system (“BESS”) includes a battery system controller and a plurality of battery packs. Each battery pack of the plurality of battery packs has a plurality of battery cells, a battery pack controller that monitors the plurality of battery cells, a battery pack cell balancer that adjusts an amount of energy stored in each battery cell of the plurality of battery cells, and a battery pack charger. The battery pack controller operates the battery pack cell balancer and the battery pack charger to control a state-of-charge of each battery cell of the plurality of battery cells. In an embodiment, the battery cells are lithium ion battery cells.

Claims

1. A battery system, comprising:

a battery stack base;

a plurality of stackable battery packs stacked on top of the battery stack base;

a battery stack controller stacked on top of one of the plurality of stackable battery packs and electrically coupled to the plurality of stackable battery packs, the battery stack controller configured to communicate with the plurality of stackable battery packs; and

a battery system controller configured to transmit charging and discharging instructions including instructions to charge only selected stackable battery packs of the plurality of stackable battery packs,

wherein each stackable battery pack of the plurality of stackable battery packs includes;

a plurality of battery cells;

a battery pack controller configured to monitor the plurality of battery cells and to adjust energy stored in the plurality of battery cells according to information received from the battery stack controller;

a plurality of battery pack dischargers, coupled to the battery pack controller, configured to individually discharge energy from each battery cell of the plurality of battery cells; and

a battery pack charger, coupled to the battery pack controller, configured to charge the plurality of battery cells of each stackable battery pack of the plurality of stackable battery packs.

2. The battery system of claim 1, wherein the battery pack controller of each stackable battery pack of the plurality of stackable battery packs is further configured to calibrate said each stackable battery pack using the plurality of battery pack dischargers and the battery pack charger of said each stackable battery pack.

3. The battery system of claim 2, wherein to calibrate said each stackable battery pack, the battery pack controller is further configured to:

instruct the battery pack charger to charge the plurality of battery cells of said each stackable battery pack until a voltage of one battery cell of the plurality of battery cells exceeds a first voltage threshold; and

instruct the plurality of battery pack dischargers to discharge the plurality of battery cells until a voltage of each battery cell of the plurality of battery cells falls below a second voltage threshold.

4. The battery system of claim 2, wherein to calibrate said each stackable battery pack, the battery pack controller is further configured to:

instruct the battery pack charger to charge the plurality of battery cells of said each stackable battery pack to raise an average cell voltage of said each stackable battery pack.

5. The battery system of claim 2, wherein the calibration of said each stackable battery pack is initiated based on a battery recalibration flag, and wherein the battery recalibration flag is set based on a recalibration trigger.

6. The battery system of claim 5, wherein the battery recalibration trigger occurs when a state of charge of at least two battery cells of the plurality of battery cells differs by more than a predefined calibration threshold.

7. The battery system of claim 1, wherein the charging and discharging instructions are active when the battery system is in an idle state.

8. The battery system of claim 1, wherein the charging and discharging instructions include at least one of a charge start time, a charge stop time, a charge duration time, a discharge start time, a discharge stop time, and a discharge duration time.

9. An electrical energy storage system, comprising:

a battery stack base;

a plurality of stackable battery packs stacked on top of the battery stack base;

a battery stack controller stacked on top of one of the plurality of stackable battery packs and electrically coupled to the plurality of stackable battery packs, the battery stack controller configured to communicate with the plurality of stackable battery packs; and

a battery system controller configured to communicate with the battery stack controller, wherein the battery system controller is further configured to transmit charging and discharging instructions including instructions to charge only selected stackable battery packs of the plurality of stackable battery packs, and

wherein each stackable battery pack of the plurality of stackable battery packs includes;

a plurality of battery cells;

a battery pack controller configured to monitor the plurality of battery cells and to adjust energy stored in the plurality of battery cells according to information received from the battery stack controller;

a plurality of battery pack dischargers, coupled to the battery pack controller, configured to individually discharge energy from each battery cell of the plurality of battery cells; and

a battery pack charger, coupled to the battery pack controller, configured to charge the plurality of battery cells of each stackable battery pack of the plurality of stackable battery packs.

10. The electrical energy storage system of claim 9, wherein the battery system controller is further configured to instruct the battery pack controller of each stackable battery pack of the plurality of stackable battery packs to calibrate said each stackable battery pack using the plurality of battery pack dischargers and the battery pack charger of said each stackable battery pack.

11. The electrical energy storage system of claim 10, wherein to calibrate said each stackable battery pack, the battery pack controller is further configured to:

instruct the battery pack charger to charge the plurality of battery cells of said each stackable battery pack until a voltage of one battery cell of the plurality of battery cells exceeds a first voltage threshold; and

instruct the plurality of battery pack dischargers to discharge the plurality of battery cells until a voltage of each battery cell of the plurality of battery cells below a second voltage threshold.

12. The electrical energy storage system of claim 10, wherein to calibrate said each stackable battery pack, the battery pack controller is further configured to:

instruct the battery pack charger to charge the plurality of battery cells of said each stackable battery pack to raise an average cell voltage of said each stackable battery pack.

13. The electrical energy storage system of claim 10, wherein the calibration of said each stackable battery pack is initiated based on a battery recalibration flag, and wherein the battery recalibration flag is set based on a recalibration trigger.

14. The electrical energy storage system of claim 13, wherein the battery recalibration trigger occurs when a state of charge of at least two battery cells of the plurality of battery cells differs by more than a predefined calibration threshold.

15. The electrical energy storage system of claim 9, wherein the charging and discharging instructions are active when the electrical energy storage system is in an idle state.

16. The electrical energy storage system of claim 9, wherein the charging and discharging instructions include at least one of a charge start time, a charge stop time, a charge duration time, a discharge start time, a discharge stop time, and a discharge duration time.