ENERGY STORAGE SYSTEM FOR HYBRID ELECTRIC VEHICLE

• US 20140017530A1
• Filed: 06/06/2013
• Published: 01/16/2014
• Est. Priority Date: 12/07/2010
• Status: Active Grant

• Current Assignee: Allison Transmission Incorporated (Allison Transmission Holdings Incorporated)
• Original Assignee: Allison Transmission Incorporated (Allison Transmission Holdings Incorporated)
• Inventors: Youngs, Daniel J., Biehl, Kurt, Bass, Edward, Schneider, Eric D., Bailey, Felice E., Reyburn, Steven T.
• Granted Patent: US 9,415,674 B2
• Time in Patent Office: Days
• US Class Current: 429/62
• CPC Class Codes: B60K 2006/4825 Electric machine connected or connectable to gearbox input shaft
• 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 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 15/2054 by controlling transmissions or clutches
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2240/26 Vehicle weight
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 2250/12 by confirmation, e.g. of the input
• CPC Class Codes: B60L 2250/16 by display
• CPC Class Codes: B60L 2270/145 Structure borne vibrations
• CPC Class Codes: B60L 2270/20 Inrush current reduction, i.e. avoiding high currents when connecting the battery
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/0084 relating to control modules
• CPC Class Codes: B60L 3/108 whilst braking, i.e. ABS
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/30 : using propulsion power stored mechanically, e.g. in fly-wheels
• CPC Class Codes: B60L 50/64 : Constructional details of batteries specially adapted for electric vehicles
• 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 58/20 : having different nominal voltages
• CPC Class Codes: B60L 58/21 : having the same nominal voltage
• CPC Class Codes: B60L 58/26 : by cooling
• CPC Class Codes: B60Y 2400/112 : Batteries
• CPC Class Codes: F28F 9/00 : Casings; Header boxes; Auxiliary supports for elements; Auxiliary members within casings
• CPC Class Codes: G01K 1/146 : arrangements for moving thermometers to or from a measuring position
• 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 10/482 : for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/486 : for measuring temperature
• CPC Class Codes: H01M 10/613 : Cooling or keeping cold
• CPC Class Codes: H01M 10/617 : for achieving uniformity or desired distribution of temperature
• CPC Class Codes: H01M 10/625 : Vehicles
• CPC Class Codes: H01M 10/637 : characterised by the use of reversible temperature-sensitive devices, e.g. NTC, PTC or bimetal devices; characterised by control of the internal current flowing through the cells, e.g. by switching means for preventing undesired use or discharge H01M50/572
• CPC Class Codes: H01M 10/6551 : Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• CPC Class Codes: H01M 10/6554 : Rods or plates
• CPC Class Codes: H01M 10/6563 : with forced flow, e.g. by blowers
• CPC Class Codes: H01M 10/658 : by thermal insulation or shielding
• CPC Class Codes: H01M 2010/4278 : Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
• CPC Class Codes: H01M 2200/00 : Safety devices for primary or secondary batteries
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/204 : Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/244 : Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• CPC Class Codes: H01M 50/264 : for cells or batteries, e.g. straps, tie rods or peripheral frames
• CPC Class Codes: H01M 50/271 : Lids or covers for the racks or secondary casings
• CPC Class Codes: H01M 50/289 : characterised by spacing elements or positioning means within frames, racks or packs spacing elements inside cells other than separators, membranes or diaphragms H01M50/471
• CPC Class Codes: H01M 50/30 : Arrangements for facilitating escape of gases
• CPC Class Codes: H01M 50/317 : Re-sealable arrangements
• CPC Class Codes: H01M 50/569 : Constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals battery terminal connectors with integrated measuring arrangements G01R31/364
• CPC Class Codes: H01M 50/574 : Devices or arrangements for the interruption of current
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• 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
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y10S 903/907 : Electricity storage, e.g. battery, capacitor

Abstract

An energy storage system comprising at least one energy storage module adapted to supply electrical energy to a hybrid vehicle. The energy storage module comprises a primary enclosure, at least one battery array located within the primary enclosure, and an energy storage controller module located within the primary. The energy storage controller module is further connected to a hybrid control module of the hybrid vehicle by a low voltage connecter. A high voltage junction box is attached to a first end of the primary enclosure and having a plurality of high voltage connection terminals. At least one of the high voltage connection terminals is configured to receive a high voltage conductor connected between the energy storage module and an inverter of the hybrid vehicle. When multiple energy storage modules are used in conjunction, one module functions as a master module and one module functions as a slave module.

Claims

1. An energy storage system, comprising:

at least one energy storage module adapted to supply electrical energy to a hybrid electric vehicle, the energy storage module comprising;

a primary enclosure;

at least one battery array located within the primary enclosure;

an energy storage controller module located within the primary enclosure and electrically connected to the battery array, the energy storage controller module further connected to a hybrid control module of the hybrid electric vehicle by a low voltage connecter; and

a high voltage connection terminal configured to receive a high voltage conductor connected between the energy storage module and an inverter of the hybrid electric vehicle;

wherein the energy storage system includes at least two energy storage modules, a first one of the energy storage modules configured to operate as a master energy storage module and a second one of the energy storage modules configured to operate as a slave energy storage module; and

wherein the master energy storage module is in operative communication with the slave energy storage module and communicates information from the slave energy storage module to the hybrid control module.

3. The energy storage system of claim 1, wherein the energy storage system is configured to periodically verify that the master energy storage module is functional;

and

wherein the slave energy storage module is configured to communicate directly with the hybrid control module if the master energy storage module is not functional.

4. The energy storage system of claim 1, wherein at least one of the energy storage modules is assigned to be a master or a slave based on the presence of electrical jumpers within the low voltage signal connector.

5. The energy storage system of claim 1, wherein the at least one energy storage module comprises:

at least two energy storage modules connected in series.

6. The energy storage system of claim 1, wherein the at least one energy storage module comprises:

at least two energy storage modules connected in parallel.

7. The energy storage system of claim 1, wherein the at least one energy storage module comprises:

a first pair of energy storage modules comprising a first energy storage module and a second energy storage module connected in parallel; and

a second pair of energy storage modules comprising a third energy storage module and a fourth energy storage module connected in parallel;

wherein the first pair and second pair are collectively connected in series.

2. (canceled)

8. An energy storage system for a hybrid electric vehicle, comprising:

at least one energy storage module adapted to supply electrical energy to the hybrid electric vehicle, the energy storage module comprising;

a primary enclosure;

at least one battery array located within the primary enclosure;

an energy storage controller module located within the primary enclosure and electrically connected to the battery array, the energy storage controller module further connected to a hybrid control module of the hybrid electric vehicle by a low voltage connecter; and

at least one high voltage junction box attached to a first end of the primary enclosure and having a plurality of high voltage connection terminals, wherein at least one of the high voltage connection terminals is configured to receive a high voltage conductor connected between the energy storage module and an inverter of the hybrid electric vehicle; and

wherein the high voltage junction box includes an outer access cover and an inner safety cover, wherein both the outer access cover and the inner safety cover must be removed to gain access to the high voltage connection terminals.

9. The energy storage system of claim 8, wherein the at least one energy storage module comprises:

a first and second energy storage module, the first energy storage module configured to be stacked upon the second energy storage module.

10. The energy storage system of claim 9, wherein the first energy storage module includes a plurality of indentations in a top surface of the primary enclosure, the indentations configured to receive a corresponding plurality of downwardly protruding feet in a bottom surface of an upper adjacent energy storage module.

11. The energy storage system of claim 9, wherein the primary enclosure includes a plurality of indentations in at least one sidewall of the primary enclosure, the indentations providing clearance for a corresponding plurality of vertically-oriented fasteners to secure the first energy storage module to the second energy storage module.

12. An energy storage system for a hybrid electric vehicle, comprising:

at least one energy storage module adapted to supply electrical energy to the hybrid electric vehicle, the energy storage module comprising;

a primary enclosure;

at least one battery array located within the primary enclosure;

an energy storage controller module located within the primary enclosure and electrically connected to the battery array, the energy storage controller module further connected to a hybrid control module of the hybrid electric vehicle by a low voltage connecter;

a fan located within the primary enclosure;

an air inlet located in a sidewall of the primary enclosure;

an air outlet located in the sidewall of the primary enclosure;

an inlet cover external to the primary enclosure and mounted adjacent to the air inlet; and

an outlet cover external to the primary enclosure and mounted adjacent to the air outlet;

wherein the inlet cover allows incoming air to be drawn through the inlet and into the primary enclosure by the fan; and

wherein the outlet cover allows outgoing air to be directed through the outlet and out of the primary enclosure by the fan.

13. The energy storage system of claim 12, wherein the air inlet and air outlet are located on the same end of the primary enclosure.

14. The energy storage system of claim 12, wherein the at least one battery array comprises:

a first and second battery array disposed generally parallel lengthwise within the primary enclosure; and

a plenum disposed lengthwise between the first and second battery arrays;

wherein the incoming air is directed from the air inlet to the first battery array by the plenum; and

wherein the incoming air is further directed to the second battery array by the plenum.

15. The energy storage system of claim 14, wherein the plenum is tapered from the first end of the primary enclosure to the second end of the primary enclosure.

16. The energy storage system of claim 12, wherein at least one of the inlet cover and outlet cover include an internal air deflector.

17. The energy storage system of claim 12, wherein a filter is disposed within at least one of the inlet cover or outlet cover.

18. The energy storage system of claim 12, wherein the energy storage module further comprises an inlet air sensor in communication with the energy storage controller module.

19. The energy storage system of claim 12, wherein the energy storage module further comprises:

an exhaust vent located in the primary enclosure; and

a battery exhaust manifold which is adapted to collect exhaust gases from a plurality of battery cells located in the at least one battery array, the exhaust manifold further adapted to direct the exhaust gases out of the primary enclosure through the exhaust vent.

20. (canceled)

21. (canceled)