System and method for electrical vehicle battery management

• US 9,537,330 B2
• Filed: 08/10/2009
• Issued: 01/03/2017
• Est. Priority Date: 08/08/2008
• Status: Expired due to Fees

• Current Assignee: Penny & Giles Controls Ltd. (Curtiss-Wright Corporation)
• Original Assignee: Penny & Giles Controls Ltd. (Curtiss-Wright Corporation)
• Inventors: Crane, Jolyon M.
• Primary Examiner(s): Rodas, Richard Isla
• Assistant Examiner(s): Henze-Gongola, David V
• Application Number:
  US13/057,550
• Publication Number:
  US 20110133690A1
• Time in Patent Office: 2,703 Days
• Field of Search: 320/119, 320/107, 320/160, 324/427, 324/428
• US Class Current: 1/1
• CPC Class Codes: B60L 58/21 having the same nominal voltage
• CPC Class Codes: G01R 31/382 Arrangements for monitoring battery or accumulator variables, e.g. SoC
• CPC Class Codes: G01R 31/3828 using current integration
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/443 in response to temperature
• CPC Class Codes: H02J 7/0016 using shunting, discharge or bypass circuits
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02J 7/0069 Charging or discharging for charge maintenance, battery initiation or rejuvenation
• 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

A powered system has a charging system and a controller arrangement. The charging system is capable of recharging the multi-cell power supply for the system and the controller arrangement enables selection between alternative modes of operation of the system. The charging system is arranged to operate in different regimes in which a target charging voltage across one or more cells or batteries is set to a different level dependent upon the selected mode of operation. There is provided a mode for optimizing the battery management for maximum range or, alternatively, a mode for extending charge and discharge cycle life of the multi-cell power supply. There is also a storage mode where the target voltage is set to a minimum value.

Claims

1. A control system for use with an electrically powered vehicle having a rechargeable multi-cell power supply including a plurality of rechargeable power cells as well as motor drive circuitry that is selectively activated to drive at least one motor/generator, the control system including:

a vehicle controller that is in communication with but discrete from a charge controller, wherein the vehicle controller and the charge controller have a first configuration different from a second configuration;

wherein, in the first configuration, the motor drive circuitry is decoupled from the rechargeable multi-cell power supply and the charge controller couples an external power supply to the rechargeable multi-cell power supply and charges the rechargeable power cells of the power supply by i) switching amongst different regimes in which a target charging voltage across one or more of the rechargeable power cells is set to different levels, and ii) calculating first data representative of the amount of charge delivered to the power supply in the first configuration; and

wherein, in the second configuration, the motor drive circuitry is coupled to the rechargeable multi-cell power supply and the vehicle controller controls the motor drive circuitry for driving the at least one motor/generator in response to operator input whereby the at least one motor/generator uses current supplied by the rechargeable multi-cell power supply or generates charging current for supply to the rechargeable multi-cell power supply, and the vehicle controller calculates and renders information concerning level of charge of the power supply based on the first data calculated in the first configuration, and the vehicle controller calculates a difference between second data representative of the charge drawn from the power supply in the second configuration and third data representative of the amount of charge delivered to the power supply in the second configuration and then subsequently uses the difference between the second and third data to update and render the information concerning level of charge of the power supply.

2. A control system according to claim 1, wherein:

the target charging voltage corresponds to a maximum charging voltage.

3. A control system according to claim 1, wherein:

the target charging voltage corresponds to a minimum discharge voltage.

4. A control system according to claim 1, wherein:

the charge controller is arranged such that charging of the rechargeable power cells of the power supply is controlled by setting parameter limits selected from the group including maximum permitted cell charge and minimum permitted cell charge.

5. A control system according to claim 1, further comprising:

a monitor arrangement to monitor a parameter of one or more of the rechargeable power cells, said parameter selected from the group including the cell voltage and cell temperature.

6. A control system according to claim 1, further comprising:

a monitor arrangement that monitors cell voltages for respective rechargeable power cells, and the charge controller is adapted to adjust the charging regime for the respective rechargeable power cells in response to the corresponding cell voltages input from the monitor arrangement, such that separate rechargeable power cells may be subject to different charging regimes.

7. A control system according to claim 1, further comprising:

a monitor arrangement that monitors cell temperatures for respective rechargeable power cells, and the charge controller is adapted to adjust the charging regime for the respective rechargeable power cells in response to the corresponding cell temperatures input from the monitor arrangement, such that separate rechargeable power cells may be subject to different charging regimes.

8. A control system according to claim 1, further comprising:

a monitor arrangement, wherein the charge controller is arranged to initiate a charge balancing function for the rechargeable power cells of the power supply in response to the input from the monitoring arrangement.

9. A control system according to claim 8, wherein:

said monitor arrangement monitors voltages for respective rechargeable power cells of the power supply; and

said charge controller is adapted to determine if the voltages for certain rechargeable power cells of the power supply are different by a predetermined amount and initiate the charge balancing function in response thereto, whereby the charge balancing function alters the charging regime to reduce differences between such voltages.

10. A control system according to claim 9, wherein:

the charge balancing function is implemented using a balancing arrangement which diverts charge away from certain rechargeable power cells until the differences between such voltages is reduced.

11. A control system according to claim 1, wherein:

the vehicle controller renders a charge state display for the user to review.

12. A control system according to claim 1, wherein:

the charge controller enables disconnection of the rechargeable power cells of the power supply from the vehicle controller when the rechargeable power cells of the power supply is to be charged.

13. A control system according to claim 12, further comprising:

charge balancing means for adjusting the distribution of charge within the separate rechargeable power cells of the power supply.

14. A control system according to claim 1, further comprising:

a circuit having a 3 terminal input port.

15. A control system according to claim 1, wherein:

the rechargeable power cells of the power supply are lithium ion batteries.

16. A control system according to claim 1, wherein:

the second data is calculated from current values derived from operating parameters.

17. A control system according to claim 1, wherein:

the second data is calculated from measured current values.

18. A control system according to claim 1, wherein:

the first data is calculated by means of monitoring the number of coulombs delivered to the rechargeable power cells of the power supply.

19. A control system according to claim 1, further comprising:

a monitoring arrangement that monitors cell voltage for the respective rechargeable power cells of the power supply;

wherein the charge controller is adapted to adjust the charging regime for the respective rechargeable power cells of the power supply in response to corresponding cell voltages input from the monitor arrangement, such that separate rechargeable power cells are subject to different charging regimes.

20. A control system according to claim 1, further comprising:

a monitoring arrangement that monitors cell temperature for the respective rechargeable power cells of the power supply;

wherein the charge controller is adapted to adjust the charging regime for the respective rechargeable power cells of the power supply in response to corresponding cell temperatures input from the monitor arrangement, such that separate rechargeable power cells are subject to different charging regimes.

21. A control system according to claim 1, wherein:

the charge controller is arranged to initiate a charge balancing function for the rechargeable power cells of the power supply in response to the input from a monitoring arrangement that monitors for the respective rechargeable power cells of the power supply.

22. A control system according to claim 21, wherein:

said monitor arrangement monitors voltages for respective rechargeable power cells of the power supply; and

said charge controller is adapted to determine if the voltages for certain rechargeable power cells of the power supply are different by a predetermined amount and initiate the charge balancing function in response thereto, whereby the charge balancing function alters the charging regime to reduce differences between such voltages.

23. A control system according to claim 22, wherein:

the charge balancing function is implemented using a balancing arrangement which diverts charge away from certain rechargeable power cells until the differences between such voltages is reduced.

24. An electrically powered vehicle device, comprising:

a rechargeable multi-cell power supply including a plurality of rechargeable power cells; and

the control system of claim 1.

25. A control system according to claim 1, wherein:

the vehicle controller is switched ON in the second configuration.

26. A control system according to claim 1, wherein:

an operator inputs a vehicle drive command in the second configuration.

27. A method of charging a rechargeable multi-cell power supply of an electrically powered vehicle having motor drive circuitry that is selectively activated to drive at least one motor/generator, wherein the rechargeable multi-cell power supply includes a plurality of rechargeable power cells, the method comprising:

providing a vehicle controller that is in communication with but discrete from a charge controller;

operating the vehicle controller and the charge controller in a first configuration wherein the motor drive circuitry is decoupled from the rechargeable multi-cell power supply and the charge controller couples an external power supply to the rechargeable multi-cell power supply and charges the rechargeable power cells of the power supply by i) switching amongst different regimes in which a target charging voltage across one or more of the rechargeable power cells is set to different levels, and ii) calculating first data representative of the amount of charge delivered to the power supply in the first configuration; and

operating the vehicle controller and the charge controller in a second configuration different from the first configuration, wherein, in the second configuration, the motor drive circuitry is coupled to the rechargeable multi-cell power supply and the vehicle controller controls the motor drive circuitry for driving the at least one motor/generator in response to operator input whereby the at least one motor/generator uses current supplied by the rechargeable multi-cell power supply or generates charging current for supply to the rechargeable multi-cell power supply, and the vehicle controller calculates and renders information concerning level of charge of the power supply based on the first data calculated in the first configuration, and the vehicle controller calculates a difference between second data representative of the charge drawn from the power supply in the second configuration and third data representative of the amount of charge delivered to the power supply in the second configuration and then subsequently uses the difference between the second and third data to update and render the information concerning level of charge of the power supply.