BATTERY PACK MAINTENANCE FOR ELECTRIC VEHICLE

• US 20110300416A1
• Filed: 06/03/2011
• Published: 12/08/2011
• Est. Priority Date: 06/03/2010
• Status: Abandoned Application

• Current Assignee: Midtronics Incorporated
• Original Assignee: Midtronics Incorporated
• Inventors: Bertness, Kevin I.
• Application Number:
  US13/152,711
• Publication Number:
  US 20110300416A1
• Time in Patent Office: Days
• US Class Current: 429/49
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• CPC Class Codes: B60L 50/62 charged by low-power generators primarily intended to support the batteries, e.g. range extenders
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 53/65 involving identification of vehicles or their battery types
• CPC Class Codes: B60L 53/80 Exchanging energy storage elements, e.g. removable batteries
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/21 having the same nominal voltage
• CPC Class Codes: B60L 58/22 Balancing the charge of battery modules
• CPC Class Codes: G01R 31/385 Arrangements for measuring battery or accumulator variables for monitoring G01R31/382
• CPC Class Codes: H01M 10/4207 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/4285 Testing apparatus
• CPC Class Codes: H01M 10/54 Reclaiming serviceable parts of waste accumulators
• 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 10/62 Hybrid vehicles
• 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 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: Y02W 30/84 : Recycling of batteries or fuel cells
• CPC Class Codes: Y04S 30/14 : Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing

Abstract

A method and apparatus for repairing or testing a used battery pack from an electric vehicle include removing the battery pack from the vehicle. Battery tests are performed on at least some of the plurality of batteries and battery test results for each of the batteries tested are obtained. A cradle is configured to receive at least two different types of batteries. The cradle includes connectors to electrically couple circuitry of a battery tester to the battery.

Claims

1. A method of repairing a used battery pack from an electric vehicle, comprising:

removing the battery pack from the vehicle, the battery pack comprising a plurality of batteries;

performing battery tests on at least some of the plurality of batteries, obtaining a battery test result for the batteries tested and storing the battery test results in a database;

obtaining a plurality of replacement batteries;

performing battery tests on the plurality of replacement batteries, obtaining a test result the replacement batteries and storing the battery test results in the database;

retrieving the battery test results from the database; and

identifying batteries based upon the retrieved battery test results for use in forming a refurbished battery pack.

2. The method of claim 1 wherein the step of identifying batteries comprises applying selection criteria to the battery test results stored in the database.

3. The method of claim 2 wherein the selection criteria is based upon an adjustable parameter of the batteries, the method further including adjusting the adjustable parameter of at least one battery.

4. The method of claim 2 wherein the selection criteria is based upon an adjustable parameter of the batteries, wherein the selection criteria applies a lower weighting function to the adjustable parameter relative to a nonadjustable parameter.

5. The method of claim 2 wherein the selection criteria includes comparing parameters of batteries to each other and identifying parameters which are within a selected range.

6. The method of claim 2 wherein the selection criteria is based upon multiple parameters of the batteries.

7. The method of claim 1 including storing battery identification information in the database which is associated with a test result for a particular battery.

8. The method of claim 1 including implementing the database in a computer memory.

9. The method of claim 1 wherein the battery test comprise applying a forcing function to a battery and observing a result.

10. The method of claim 1 wherein the batteries comprise individual cells.

11. The method of claim 1 wherein the batteries comprise groups of cells.

12. The method of claim 1 wherein performing battery tests on the batteries in the battery pack is performed prior to removing the battery pack from the vehicle.

13. The method of claim 1 wherein performing battery tests on the batteries in the battery pack is performed subsequent to removing the battery pack from the vehicle.

14. The method of claim 1 wherein the replacement batteries are obtained from another battery pack.

15. The method of claim 1 wherein the replacement batteries comprise new batteries.

16. The method of claim 1 including identifying a configuration of batteries for placement in the refurbished battery pack based upon the battery test results.

17. The method of claim 1 including implementing the step of identifying in a computer.

18. The method of claim 1 including placing the battery pack in a cradle which is coupled to battery test circuitry.

21. The apparatus of claim 18 wherein the selection criteria is based upon an adjustable parameter of the batteries, the controller further configured to adjust the adjustable parameter of at least one battery.

19. An apparatus for use in refurbishing a used battery pack from the electric vehicle, comprising:

battery test circuitry configured to perform battery tests on batteries in the used battery pack;

a database configured to contain battery identification information and at least one associated battery parameter obtained from the battery test circuitry;

a selection criteria which identifies batteries for use in creating a refurbished battery pack; and

a controller configured to retrieve information from the database, apply the selection criteria and responsively provide selection information output which indicates which of the batteries identified in the database are suitable for use in creating a refurbished battery pack.

20. The apparatus of claim 19 wherein the selection criteria includes comparing parameters of batteries to each other and identifying parameters which are within a selected range.

22. The apparatus of claim 20 wherein the selection criteria is based upon an adjustable parameter of the batteries, wherein the selection criteria applies a lower weighting function to an adjustable parameter relative to a nonadjustable parameter.

23. The apparatus of claim 19 wherein the selection criteria is based upon multiple parameters of the batteries.

24. The apparatus of claim 19 wherein the database includes battery identification information associated with a test result for a particular battery.

25. The apparatus of claim 19 wherein the battery test comprises applying a forcing function to a battery and observing a result.

26. The apparatus of claim 19 wherein the batteries comprise individual cells.

27. The apparatus of claim 19 wherein the batteries comprise groups of cells.

28. The apparatus of claim 19 wherein the selection information output includes information identifying a configuration of batteries for placement in the refurbished battery pack based upon the battery test results.

29. The apparatus of claim 19 including a cradle coupled to the battery test circuitry configured to receive a battery and couple the battery to the battery test circuitry.

30. The apparatus of claim 29 including circuitry coupled to the cradle configured to select a polarity of an electrical connection to the battery.

31. An apparatus for testing a battery of a battery pack from an electric vehicle, comprising:

test circuitry configured to perform a battery test on the battery;

a cradle configured to receive the battery, the cradle comprising;

first and second connectors configured to electrically connect the test circuitry to end connectors of the battery; and

a midpoint connector configured to electrically connect the test circuitry to an electrical midpoint between the end connectors.

32. The apparatus of claim 31 wherein the cradle includes a lock mechanism to secure the battery in the cradle.

33. The apparatus of claim 31 wherein the cradle includes a temperature sensor.

34. The apparatus of claim 31 wherein the midpoint connector includes a plurality of electrical connectors configured to couple to a plurality of electrical midpoints between the end connectors of the battery.

35. The apparatus of claim 31 including a second midpoint connector configured to couple to additional midpoint connections between the end connectors of the battery.

36. The apparatus of claim 35 wherein the midpoint connectors are positioned opposite one another.

37. The apparatus of claim 35 wherein the second midpoint connector is carried on a slidable portion.

39. The apparatus of claim 37 wherein the cradle includes a cover configured to cover the battery.

40. The apparatus of claim 39 wherein the cradle includes a switch actuated by the cover when the cover is in a closed position.

41. The apparatus of claim 31 wherein the test circuitry is configured to measure a dynamic parameter of the battery.

42. The apparatus of claim 31 including polarity switching circuitry configured to selectively switch polarity of the first and second connectors coupled to the test circuitry.

43. The apparatus of claim 34 including polarity switching circuitry configured to switch polarity of the electrical connectors coupled to the electrical midpoints.

44. The apparatus of claim 31 wherein the first and second connectors comprise Kelvin connections.

38. The apparatus of claim 38 including a lock mechanism to secure the slidable portion to a base of the cradle.