Battery system and management method

• US 9,577,443 B2
• Filed: 02/25/2013
• Issued: 02/21/2017
• Est. Priority Date: 06/03/2010
• Status: Active Grant

• Current Assignee: C&C Power Incorporated
• Original Assignee: C&C Power Incorporated
• Inventors: Gach, Eric, Fechalos, William, Conrardy, N. William
• Primary Examiner(s): Muralidar, Richard V
• Application Number:
  US13/775,753
• Publication Number:
  US 20140239964A1
• Time in Patent Office: 1,457 Days
• Field of Search: 320/132, 320/152, 320157-159, 320162-164, 702/63
• US Class Current: 1/1
• CPC Class Codes: G01R 31/36 Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
• CPC Class Codes: G01R 31/367 Software therefor, e.g. for battery testing using modelling or look-up tables
• CPC Class Codes: G01R 31/382 Arrangements for monitoring battery or accumulator variables, e.g. SoC
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0016 using shunting, discharge or bypass circuits
• CPC Class Codes: H02J 7/00302 Overcharge protection
• CPC Class Codes: H02J 7/00309 Overheat or overtemperature protection

Abstract

A system and method for monitoring the status of a system of battery strings is described. The battery string current is measured by a current sensor urged into contact with a metallic element in which the battery string current is flowing. The time history of the battery string current and voltage is interpreted to determine whether the battery string is discharging, charging or in a fully charged state. A moving average current in the charging state is used to establish a threshold for determining whether a thermal runaway condition exists. The moving average is maintained at the value that existed at a time when the battery string has been disconnected from the system current bus.

Claims

1. A storage battery system runaway protection unit, comprising:

a current sensor;

a voltage sensor connected across a series string of storage batteries;

a processor configured to accept data from the current sensor and the voltage sensor and to;

determine a charging state of the series string of storage batteries;

compute a measure of the state of charge of the series string of storage batteries;

compare a measured current of the current sensor with a state dependent threshold current;

set a threshold current and a delay time criteria for each of a fully charged state and a charging state, wherein a threshold in the charging state is related to an averaged battery string current value for the charging state; and

provide a warning or control signal output when the measured current exceeds the threshold current for a predetermined delay time.

2. The unit of claim 1, wherein the current sensor further comprises:

a pair of conductive probes urged into contact with a metallic element connected in series with a series string of batteries, the probes oriented substantially along a direction of current flow in the metallic element.

3. The unit of claim 2, wherein the metallic element is a bus bar.

4. The unit of claim 1, wherein the current sensor is a Hall effect current sensor.

5. The unit of claim 1, wherein the charging state is one of:

discharging, charging or float charging.

6. The unit of claim 5, wherein the charging state comprises a plurality of sub states, including normal charging and disconnected from a load.

7. The unit of claim 1, where the state of charge of the battery is a measure of an amount of energy in the battery and decreases during discharge events and is constant or increases during charging events.

8. The unit of claim 7, wherein the state of charge of the battery is a maximum during a float charging state.

9. The unit of claim 1, wherein the state of charge is computed by multiplying the current by a first constant during a discharging state and by a second constant during the charging state.

10. The unit of claim 1, wherein the computed state of charge is adjusted to be a maximum value when the charging state is a float charging state.

11. The unit of claim 9, wherein the adjustment is to increase the absolute value of the second constant and to continue to compute the state of charge until the maximum value is reached.

12. The unit of claim 11, wherein the second constant is adjusted after each charging cycle to provide an estimate of the state of charge that is closer to the maximum value when a floating charging state is reached.

13. The unit of claim 1, wherein a tracking current value is computed as low pass filtered version of the battery string current during the charging state, except that the value is maintained at the value that obtains during a period where the string current is zero and a string voltage is substantially an operating voltage.

14. The unit of claim 13, wherein the measured current in each of the charging and discharging states is compared with a threshold value corresponding to the charging state.

15. The unit of claim 14, wherein the threshold value is at least one of a value proportional to the tracking current, a predetermined increase of the tracking current, or a fixed current value.

16. The unit of claim 15, wherein a delay time is associated with each threshold value.

17. The unit of claim 16, wherein an alarm type or control signal type is associated with combinations of threshold values, delay times and charging states and wherein the alarm or control signal is output when an associated combination of threshold value and delay time is exceeded.

18. The unit of claim 1, wherein the control signal activates a disconnect switch to isolate the battery string from a system current bus.

19. The unit of claim 1, wherein the current sensor includes voltage source having a high impedance with respect to a resistance of a metallic element circuit between a pair of probes, the voltage source connected to one probe of the pair of probes.

20. The unit of claim 1, where an offset voltage between input terminals of an amplifier is measured by one of connecting two input terminals to a common point, by measuring a fixed voltage, or by interchanging the connections between a pair of probes and the input terminals.

21. The unit of claim 1, further comprising a temperatures sensor in thermal contact with a metallic element, providing a temperature measurement to the processor, wherein the processor adjusts a value of measured current based on an estimate of a resistance of the metallic element as a function of temperature.

22. A method of protecting a storage battery system from thermal runaway, comprising:

measuring a current of a storage battery string

measuring a voltage of the storage battery string;

determining a charging state of battery string as one of charging, discharging or fully charged;

determining the state of charge of the storage battery string;

determining threshold current and delay time criteria for each of a fully charged state and a charging state, wherein a threshold in the charging state is related to an averaged battery string current value for the charging state; and

providing an alarm or control signal when the threshold in the charging state or in the fully charged state is exceeded by the measured current for greater than the delay time criteria for the threshold.

23. The method of claim 22, wherein a plurality of thresholds and delay time criteria is established in each of the charging states of charging and fully charged, and a specific alarm or control signal is associated with a determination that a threshold and delay time has been exceeded.

24. The method of claim 22, wherein, when the charging state is charging, and the current is zero while the voltage is substantially the battery string voltage, the charging state is maintained as charging until the current is non-zero, and the state of charge.

25. The method of claim 22, wherein the average current value is determined as a low-pass filtered value of the current in the charging state, excluding any interruptions in a charging process.

26. The method of claim 22 wherein the state of charge of the battery string is determined by a counter that is decremented at a first rate during a discharging state having a first constant of proportionality to the battery string current and incremented at a second rate during a charging period having a second constant of proportionality to the battery string current, except that the counter is not incremented when the battery string current is zero and the voltage is substantially the battery string voltage.

27. The method of claim 26, wherein the second constant of proportionality is adjusted to minimize a time difference between the counter reaching a fully charged value and the time when the average battery string current indicates that the battery string is fully charged.

28. The method of claim 22, wherein at least one threshold value in the charging state is proportional to the averaged battery string current.

29. The method of claim 22, wherein at least one threshold in the charging state is a sum of a constant and an averaged measured current.

30. The method of claim 22, wherein at least one threshold value in the fully charged state is a constant current value.

31. A software program product, stored on a non-transitory medium, comprising:

instructions executable by a processor to perform the steps of;

measuring a current of a battery string

measuring a voltage of the battery string;

determining the charging state of battery string as one of charging, discharging or fully charged;

determining a state of charge of the battery string;

determining threshold current and delay time criteria for each of a fully charged state and a charging state, wherein a threshold in the charging state is related to an averaged battery string current value for the charging state; and

providing an alarm or control signal when the threshold in a charging state or in a fully charged state is exceeded by the measured current for greater than the delay time criteria for the threshold.