WO2017203265A1 - Procédés et appareil d'accumulation d'énergie - Google Patents

Procédés et appareil d'accumulation d'énergie Download PDF

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Publication number
WO2017203265A1
WO2017203265A1 PCT/GB2017/051488 GB2017051488W WO2017203265A1 WO 2017203265 A1 WO2017203265 A1 WO 2017203265A1 GB 2017051488 W GB2017051488 W GB 2017051488W WO 2017203265 A1 WO2017203265 A1 WO 2017203265A1
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Prior art keywords
array
controller
battery module
battery
current
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PCT/GB2017/051488
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English (en)
Inventor
Robin Shaw
Stephen Irish
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Hyperdrive Innovation Ltd
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Hyperdrive Innovation Ltd
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/509—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the type of connection, e.g. mixed connections
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/36—Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/36—Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
    • G01R31/392—Determining battery ageing or deterioration, e.g. state of health
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/4285—Testing apparatus
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/44—Methods for charging or discharging
    • H01M10/441—Methods for charging or discharging for several batteries or cells simultaneously or sequentially
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/482—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for several batteries or cells simultaneously or sequentially
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/486—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for measuring temperature
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or discharging batteries or for supplying loads from batteries
    • H02J7/50—Circuit arrangements for charging or discharging batteries or for supplying loads from batteries acting upon multiple batteries simultaneously or sequentially
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/36—Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
    • G01R31/371—Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC] with remote indication, e.g. on external chargers
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/36—Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
    • G01R31/396—Acquisition or processing of data for testing or for monitoring individual cells or groups of cells within a battery
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H01M10/4257—Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H01M2010/4271—Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H01M2010/4278—Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • This invention relates to methods and apparatus related to energy storage, and in particular to battery controllers and battery control methods, and in particular to battery control methods and apparatus for systems comprising pluralities of interconnected batteries.
  • battery powered apparatus is arranged to accept a predetermined number of batteries in a predefined arrangement.
  • one or more batteries will be installed into a pre-existing compartment with terminals or connection leads to allow the battery or battery systems to simply be plugged in.
  • This is advantageous because the size and shape of the pre-existing compartment can physically constrain the number and type of batteries which can be introduced to the apparatus. This makes it unlikely that consumers and other operators will plug unsuitable batteries into the apparatus.
  • the number and type of batteries and their electrical arrangement e.g. the arrangement of series and/or parallel connections between these batteries
  • the power delivery performance and charging demand of these batteries can be predicted with reasonable accuracy. This approach to arranging series of batteries, and sets of series of batteries arranged in parallel, has previously been thought to be entirely adequate.
  • Figure 1 includes Figure 1A which shows a type of battery module, and Figure 1 B which shows a further example of the type of battery module illustrated in Figure 1 A;
  • FIG 2 shows an array of battery modules which may comprise battery modules such as those illustrated in Figure 1 ;
  • Figure 3 shows a flow chart to describe a method of self-arbitration for implementation by apparatus such as that illustrated in Figure 1 and Figure 2;
  • FIG. 4A shows another array of battery modules
  • Figure 4B shows yet another array of battery modules
  • Figure 5 shows a flow chart to describe a method of determining the arrangement of battery modules in an array using current measurements
  • Figure 6 shows a flow chart to describe a method of determining the number of strings in an array of battery modules in an array using voltage measurements
  • Figure 7 shows a flow chart to describe a method of determining the arrangement of battery modules in an array using voltage measurements.
  • FIG. 1A illustrates a battery 100 comprising a battery controller 102.
  • This controller 102 is configured to communicate with other similar controllers with which it may be connected so that a set of battery modules having such controllers can organise themselves to operate in concert to provide improved power characteristics.
  • the ability to self-organise may be significant because it enables the array as a whole to be fault tolerant - it includes inherent redundancy because if one module fails, the array as a whole may continue to operate.
  • the battery controller is configured so that, when it is connected in communication with other such battery controllers it sends a message to those controllers. This message comprises the controller's own unique identifier.
  • each controller in this array can then be identified as the master controller.
  • This master controller may then control functions of the array as a whole such as charging control, power demand balancing across the array, and fault-finding.
  • FIG 1A shows an example of a battery 100 comprising a controller 102 configured to operate in this manner.
  • the battery 100 comprises a communication interface 103 adapted for sending and receiving messages over a communications link 1 10 to permit communication with other similar controllers.
  • the communication interface illustrated in Figure 1 comprises a serial BUS interface, such as a controller area network, CAN, interface.
  • the controller 100 comprises at least some data storage, for example in the form of nonvolatile memory. This data storage stores a unique identifier of the controller.
  • the controller is configured to operate the communication interface 103 to broadcast its unique identifier at intervals (e.g. periodic or aperiodic intervals, or in response to sensing connection to another similar battery).
  • the controller 102 is also configured to use the communications interface 103 to listen to the communications link 110 to obtain broadcast messages received from other similar controllers and to obtain from those messages the unique identifiers of those controllers.
  • the controller sends a message comprising its unique identifier. This may be done at intervals (e.g. periodically, aperiodically, or in response to a trigger such as sensing connection to another device such as a charger or another similar controller).
  • the controller 102 also listens at the communications interface 103 to receive one or more network messages from other similar controllers. Each such received message comprises a unique identifier of the controller which sent it. Each such message can also carry battery data such as battery terminal voltage.
  • the controller 102 can then identify, based on these received messages, one of these other controllers as a master controller. One way this can be achieved is by selecting a one of the controllers identified based on the values of the unique identifiers received in these messages. For example, the controller having the highest value identifier may be selected as the master.
  • the controller 102 is configured so that, in the event that it is connected in a series of batteries and designated as the master controller, it determines a charging demand for the series based on the received messages. For example, the battery terminal voltages can be obtained from the messages and summed together by the master controller to determine the voltage of the series. The controller can then send, via the communications interface, a network message comprising the charging demand via the communications interface. This too may be sent at intervals (as described above). This charging demand may be configured to cause a charger coupled to the series to provide electrical energy to the series according to the demand.
  • the controller may be configured to store the unique identifiers received from other controllers (e.g. those associated with other similar batteries). In the event that a new message is received, the controller may compare the unique identifier carried by that new message with the stored identifiers. In the event that the unique identifier does not match the stored identifiers, the controller may repeat the process of identifying which controller in the series is to be master. Yet a further example is that the controller may repeat the process of identifying the master in the event that a message comprising a particular one of the stored identifiers is not received for more than a selected interval.
  • the controller 102 may also be configured so that, in the event that it is designated as master it can control a diagnostic process of the series. Conversely, because all members of the series apply the same rules of arbitration to select the master controller, each controller knows which commands are to be obeyed. This can permit the master controller to perform one or more diagnostic processes in the series.
  • the master may simply make a charging demand based on the number of unique identifiers it has received.
  • a set of these series strings of batteries may also be arranged in parallel to provide an array - a set of series strings, each string connected in parallel with the others.
  • embodiments of the controller illustrated in Figure 1A may be configured to determine the arrangement of the electrical connections between battery modules in the array. In other words it may determine the electrical arrangement of series and parallel connections which make up the array.
  • the charging demand mentioned above may comprise both a current request and a voltage request. The current request may be based on the number of parallel strings in the array.
  • Figure 1 B shows a further example of a battery such as that shown in Figure 1A.
  • the example illustrated in Figure 1 B comprises a controller 102, three energy storage cells 104a- c; a voltage buffer 106 for providing an indication of the voltage across one of the cells 104 to the controller 102; a current sensor 108 for sensing current flowing into or out of the cells 104; a disconnector 105; and terminals 112a and 112b.
  • the controller 102 is coupled to the output of the voltage buffer 106 and to the current sensor 108.
  • the controller 102 is also coupled to control the disconnector 105, and to send and receive messages via the communication interface 103.
  • the energy storage cells 104a-104c are coupled together in series, with the current sensor 108 and the disconnector 107.
  • the current sensor 108, the disconnector 107, and the cells 104a-104c are together arranged between the terminals 112a, 1 12b so that a voltage based on the combined total voltage across the cells can be applied to the terminals 112a, 1 12b, and the current passed between the terminals can be sensed by the current sensor 108.
  • the disconnector 107 comprises an electrically operable impedance controller, such as a switch, contactor or relay or a voltage controlled impedance such as a transistor.
  • the disconnector 107 can be controlled by the controller 102 to modify the impedance of a current path between the terminals 1 12a, 112b, for example to provide an open circuit impedance between those terminals.
  • the voltage buffer 106 is arranged to provide a cell voltage to the controller 102.
  • the battery comprises one such voltage buffer for each cell to provide the controller with cell voltage data indicating the voltage of each of the cells. This may permit the controller also to operate a battery management system to balance cell voltages, for example by dissipating energy stored in one or more of the cells.
  • the controller 102 is configured to operate the communication interface to send and receive messages. These messages generally all comprise an identifier of the controller 102 and may also comprise at least one of: (a) some status information associated with the battery 100 in which the controller 102 is present and (b) one or more commands or requests. Different types of message may be involved.
  • the controller 102 is configured so that at intervals it broadcasts, via the communications interface 103, a report message comprising its unique identifier. This may permit the arbitration method described above to be carried out so that one controller of an array of batteries can be identified as a master.
  • these messages may also comprise an identifier of the device, or the type of device, for which they are intended.
  • the messages include status information this may comprise one or more parameters selected from the following list: terminal voltage; one or more individual cell voltages; battery state of charge; battery temperature; electrical current sensed by the current sensor, error flags and status indicators such as overvoltage, under-voltage, over-temperature, under-temperature indicators. Examples of different message types and the data they may contain are explained below.
  • a command message may comprise a disconnect message carrying an identifier of a controller and a command to cause the identified controller to operate its disconnector 107 to switch off the current path through the battery - e.g. to provide an open circuit voltage at the battery terminals.
  • the controller 102 is configured so that, in the event that it receives a disconnect message from a controller of the array which has been designated as the master controller, it responds by operating its disconnector 107 to provide an open circuit impedance at its terminals. To achieve this, the disconnector 105 may disconnect fully (e.g. by breaking the current flow path altogether), or it could just prevent either charging or discharging.
  • the disconnector 105 comprises a mechanical contactor the current path may be broken, whereas if it comprises a pair of back- to-back MOSFETs current flow may be switched off in only one direction.
  • the controller is also configured so that, at intervals, it sends report messages via the communications interface 103 indicating its status. These messages may reflect the connection status of the current path through the battery. It will be appreciated in the context of the present disclosure that disconnecting the current path through the battery need not disconnect the communication interface 103 from the channel 1 10.
  • a "disconnected" battery may remain connected for communications purposes (e.g. via CAN so will maintain comms with the master controller throughout the operation). The "disconnection” in this context refers to preventing or modifying current flow through the main terminals of the battery.
  • the controller 102 is configured so that in the event that it is designated as the master controller, it determines the electrical arrangement of the array in which it is connected by communicating with the other batteries in that array. Operation of the controller 102 to perform this process will now be described.
  • the controller 102 In operation, when current is being supplied to the battery (and to the series of batteries in which it is included) from a charger the controller 102 selects, from the stored list of unique identifiers, another battery of the array which is to be disconnected. The controller 102 then sends a disconnect message via the communication interface 107 to the controller 102' of the selected other battery. After the disconnect message has been sent, the controller 102 verifies that the selected battery has been disconnected based on report messages received over the communication interface from that selected battery. The controller 102 then receives report messages from the other batteries with which its communication interface 107 is able to communicate. The controller then identifies the batteries which are connected in series with the selected other battery by identifying those batteries whose report messages indicate zero current.
  • the master then knows how much current it should be receiving from the charger, and can compare this with the measured values received from the packs in the array. It can then carry out the self-test procedure and determine which packs are in each parallel string whilst controlling the current being requested from the charger, which it will use as a comparison as explained in more detail below.
  • An example of the kind of data which may be obtained by this process is outlined in the table below.
  • the master controller Prior to the master controller (designated ID 1 in the table below) sending a disconnect message, it has obtained from report messages received from other similar controllers. These report messages provide an indication of the electrical current sensed by those controllers.
  • the master controller has selected controller 3 to be disconnected, and sent a disconnect message to that controller (designated 3 in the table below). After sending the disconnect message, the master controller obtains electrical current values from further report messages received from the other controllers.
  • the master controller 102 can thus identify those other controllers (2 and 5) as being in series with the controller it selected for disconnection. It may allocate a string identifier to these batteries and store data indicating the string to which each battery has been allocated. For example, the string ID may be selected based on the battery which is selected for disconnection, but any other method of selecting an identifier for the string may also be used. An example of data which may be stored after the performance of the method explained above with reference to Table 1 is shown in Table 2. Table 2 - Allocation of Batteries to Strings
  • This process can be repeated by reconnecting the selected battery, and then disconnecting another selected battery of the array until the controller 102 has recorded data indicating the identity of the series string to which each of the different batteries belong.
  • the controller 102 may use this information about the electrical arrangement of batteries in the array to determine a charging demand for the array. For example, in the event that the controller determines that the array includes a single string, the controller may operate the communication interface to send a request message to a charger connected to the array which requests the delivery of a certain charging current. That charging current may bebased on the rated maximum of a single battery pack, multiplied by the number of parallel series (strings) of battery modules in the electrical arrangement.
  • the controller may be configured to modify (e.g. to reduce the requested current) based on cell temperatures (high or low) or based on cell voltages (as the cells with the highest state of charge reach their upper charging threshold).
  • the controller 102 may also be configured so that, in the event that it is designated as the master controller, it performs safety control of the array. This may comprise performing a diagnostic for detection of faults in the array. For example, the controller 102 may determine based on the messages it receives from other controllers whether certain safety conditions are met. If such a safety condition is not met the controller may initiate a safety action.
  • An example of a safety condition is checking that the total voltage of the batteries which make up one string match the total voltage of all other strings. Another example is checking that the current through each battery of a string matched the current through other batteries in that string. Other examples are possible.
  • the master controller may confirm if the deduced number of parallel strings of the electrical arrangement is correct by referring to the expected charge current. For example, if there are 5 parallel strings and the total charge current requested from the charger is 100A then we would expect to see 20A on each string (allow a small measurement tolerance of, a few percent). If we disconnect one string then the current on the other 4 strings should increase to 25A. However if it was measured at 33A then this indicates that the deduced arrangement is incorrect and an error state should be indicated. Accordingly, the controller may be configured to send disconnect messages to a controller belonging to a first string and to sense current through a battery of a second, different, string during that disconnection. In the event that the sensed current does not match a prediction based on the deduced electrical arrangement, the controller may trigger a safety action.
  • An example of a safety action is sending an error message and/or operating a disconnector to disconnect the batteries of the array.
  • the controller 102 can determine a charging current request, and send that request to a charger coupled to the array. The controller 102 can then determine an actual current sensed in the array, and compare that current with the charging current request. In the event that the actual current does not match the requested charging current, the controller 102 can determine that a fault has occurred and trigger a safety action.
  • the actual current may be sensed by the controller 102 using the current sensor 108 in its battery.
  • the controller 102 may also validate this 'actual current' by checking it against electrical current data received from another controller which is in the same string as that controller - e.g. it may check its own current sensor value against a current sensor value received from another battery which it has identified as being in the same string.
  • the communication interface need not be separate from the controller.
  • the controller 102 may itself be provided with a means for communicating information to the outside world to provide the communications link 110. As shown this link may be two way, that is, the link may allow for either or both of transmission and/or reception of communication signals. Alternatively, according to the desired functionality, the link may be only one way.
  • the controller 102 may communicate information relating to the battery module 100, including state of charge, output voltage of one or more cells, output current, temperature, fault messages, or configuration information relating to the controller 102 or the battery module 100.
  • the communications link 110 may allow the battery module to receive information, for example, configuration information for the module 100 or the controller 102; instructions for balancing the cells 104; requests for information relating to the module 100, or the controller 102, or one or more of cells 104; or instructions to decouple the module 100 as a whole from a wider array.
  • the communications link may be provided as a wired, wireless, or fibre optic connection, for example, or by any other means known in the art for providing communications channels. Where it is provided by a wired connection it may be mediated through the terminals 1 12a, 1 12b, for example by modulating a data signal over DC power couplings connected to the terminals.
  • the controller 102 may receive information from both the current sensor 108 and the voltage buffer 106, and uses this to determine information, such as state of charge of the cell, or general battery health, or to balance charge between the cells 104. In addition, it may communicate this information via the communications link 1 10.
  • the power output terminals 112 may be connected to an external device which requires power. In this case the external device draws power from the battery module 100, and the cells 104 deplete their charge. The charge on the cells may be replaced by connecting the battery module to a charging device, which supplied current to the cell. In each case, whether charging or discharging, information from the current sensor 108 can be used by the controller 102 to keep an accurate track of the state of charge of the battery module 100
  • additional voltage buffers could be included to provide voltage measurements the voltage across more than one cell 104 of the module 100.
  • a measurement may be taken across each cell 104 in the module 100 and supplied to the controller 102.
  • the controller 102 may use the measured current and voltage readings to perform load balancing on the cells 104. That is, the controller 102 may be configured to ensure that each cell 104 in the battery module 100 charges and discharges at the same rate, regardless of the capacity of any given cell 104 in the module 100. Such balancing may include calculating the state of charge of each cell 104 in the battery module 100, and/or diverting power from cells which have a higher state of charge into those which have a lower state of charge, in order to even out the state of charge of the cells 104 relative to one another. Power is supplied to, and drawn from, the battery module 100 via the two external power output terminals 112. While Figure 1 shows a voltage buffer as measuring the voltage of a single cell, any means for measuring the voltage may be employed.
  • any means for providing an indication of current level and/or direction may be used. While three cells 104a-c are shown as part of the battery module 100, any number of cells 104 may be included as part of a battery module.
  • the cells 104 are typically rechargeable battery cells, but may be any type of energy storage cell.
  • the module may include means for measuring the temperature, e.g. thermocouples, thermistors or other thermometry means known in the art.
  • Messages sent and/or received by the controller 102 via the communication interface 103 may comprise one or more items of the following information: Cell Voltages, Cell Temperatures, Error flags and status indicators, Other component temperatures (eg PCB, conductors, ICs), Electric current readings, Serial number, and Charger control commands. Other variations and changes to this apparatus are envisaged.
  • each string includes three battery modules connected in series using their power output terminals 212.
  • each battery module 200 is able to communicate with other battery modules in the array 201 via a series of busses 214a-c which connect the communications links 210 of each battery module 200 to one another.
  • FIG 2 a total of nine battery modules 200 are shown connected together, as described above. It will be readily apparent, however, that the size of the array 201 can be arbitrarily chosen according to the power requirements of the system. Starting from just two modules, the array can be expanded arbitrarily, including threads of any length, and as many parallel threads as required.
  • the array has overall output connections 222, to which a load can be connected to power the load, or to which a charger can be connected to recharge the cells of the array.
  • busses 214 of Figure 2 are shown as three separate busses, which allow connection between each battery module in the array, it is possible to link every battery module to the others using just a single bus, or indeed any number of busses connected together. Additional functionality of the battery modules 100, 200 shown in Figures 1 and 2 is further illustrated in Figure 3. In battery arrays such as the example in Figure 2, it can be desirable to provide a centralised control of the array, to reduce the complexity of controlling each module of the array separately. It is possible to provide the functionality required to control the entire array to each controller 102. However, the array may be able to uniquely determine which controller is control of the array (which is the master controller), and which controllers do not directly control the array, but may respond to the master controller (the slave controllers).
  • the first step 350 specifies that the controller sends a message comprising a unique controller identifier.
  • the controller identifier may be a controller serial number, or it may be any other number assigned to the controller which is unique to that array. Since each controller which forms part of a battery module can do this, a plurality of network messages will be sent, one from each controller.
  • step 352 the controller receives a network message comprising a unique identifier from each other controller of a battery module in the array.
  • each controller receives a network message from each other controller in the array.
  • the modules use the received information, and their own unique identifier to identify a single master controller. Any controller which is not the master module is a slave module.
  • the determination of which modules are master and slave modules may depend to some degree on the choice of unique identifier for the modules. As an example, if a controller serial number is used, then the controllers may determine which controller is master by ranking the serial numbers in numerical order. The rules may further specify that the controller with the lowest ranking serial number is the master controller. Since by assumption the identifier is unique, this means that every controller in the array will agree which one is the master, and which are slaves. There are many other ways in which a master controller may be determined, with the only criterion being that the result must be unique and agreed upon by every controller in the array.
  • the array itself may have a controller, which can participate in the self- arbitration. It may be desirable to make this controller the master controller by default, for example by forcing the controller serial number to be 0, following the above example, which uses the lowest serial number as the master controller.
  • the process depicted by Figure 3 may be repeated.
  • the array may be configured to detect the addition or removal of a battery module from the array, and trigger the self-arbitration process of Figure 3 in response to this. This ensures that in the event that a battery module is removed which includes the master controller, the array can easily and quickly determine a new master controller, and continue to operate. Similarly, the array may periodically perform this process, or perform it at random or semi-random intervals.
  • a master controller performs various other functions in relation the operation of the array. For example, a master controller may be responsible for determining the amount of current required from a charger, in order to charge the battery modules of the array. Similarly, the master controller may perform load balancing between the battery modules of the array, to ensure that the output current and/or voltage match the intended values, and that each battery module in the array is delivering power at a rate which will cause all battery modules to run out of charge at the same time.
  • a further process which the master module may control is that of determining the arrangement of the battery modules in the array.
  • the arrangement may be a plurality of threads connected to each other in parallel, each thread having a plurality of battery modules 200 connected in series with one another.
  • this information can, for example, be reported to a master controller by the controller in each module, communicating via the bus 214).
  • the arrangement of the modules is not known, then it can be difficult to calculate the output voltage and/or current of the array - an important parameter for determining the practical application of the array.
  • the array may be configured to determine the arrangement of the battery modules relative to one another. This may be performed by the master controller, as determined above, or it may be determined by any one of the controllers. As mentioned above, in the case where there is a master controller, this may be a controller which is part of the array, rather than, for example, the controller which is part of the battery module as shown in Figure 1.
  • FIG. 4A In order to understand the process for determining the arrangement of the battery modules in the array, consider Figure 4A. In this figure, thirteen battery modules 400a-m are shown spread between four strings. As shown, a first string comprises four modules 400a-d, a second string comprises three modules 400e-g, a third string comprises four modules 400h-k, and a fourth string comprises two modules 400l-m. It will be understood that this arrangement is merely illustrative of the possible arrangements of battery modules in an array, and that any number of strings is possible, each string comprising one or more battery modules. Moreover, the array may be structured in such a way that additional battery modules can be added to any of the strings at any time, or even added to create a new string.
  • FIG. 4A This figure is similar to Figure 4A, in that a plurality of battery modules 400a-e (in this example there are five battery modules, although any number is possible) are connected together in a plurality of strings (in this example two strings, although as described above, any number is possible), with each string having one or more battery modules 400 connected together in series.
  • Each module may communicate with one another via a bus 414.
  • the battery array 401 is provided with a predetermined number of bays, in this case six bays, into which a battery module may be inserted.
  • Each bay is provided with a bypass, for example a switch 416. In the event that a bay is occupied, the switch is left open circuit 416a, so that the battery module terminals 412 are not shorted out.
  • the switch When a bay is unoccupied, the switch may be closed, in order that the other batteries in that string maintain connectivity to the output terminals of the array 422. It is important that it is not possible to close every switch in a given string simultaneously, as this would short out other strings in the array. Compliance with this requirement may be implemented electronically, mechanically, or in any other way known to those in the art. Similarly, as discussed above, it is important that the switch of a given bay is not closed when a battery module is occupying that bay. This may be ensured by physical design of the battery modules, which can be designed to force a break-before-make connection in the sense that the switch is opened prior to mounting the module in a bay, and inhibiting (for example preventing) closure of the switch while a module is occupying the bay.
  • a controller need only have rudimentary knowledge of the array, in order to determine the arrangement. For example, if the controller is provided with a map of the bays of the array (that is, it knows that there are m parallel strings, and it further knows how many bays are in each string), and the switches are arranged to communicate whether they are open or closed, then the controller can immediately determine how many strings are occupied, and which bays of which strings are occupied. This is enough to determine at a basic level the arrangement of the battery modules. More detailed information can be provided to the controller if each switch is also configured to provide information relating to its physical position in the array.
  • a more detailed determination may be made by providing the battery modules and/or the bays with a means for allocating an identifier to the battery module. This may be fixed to the bay, so that any battery module mounted in such a bay automatically takes on this identifier.
  • the controller is then arranged to associate this identifier with a particular battery module's battery information, for example state of charge, output voltage, current etc., all of which can be communicated to the controller, for example via the bus.
  • each battery module is provided with a DIP switch, or other manually configurable identification device.
  • the identification device can be set to a unique value indicative of the battery module's position in the array. For example, a first portion of the identification value could represent the string number, and a second portion of the identification value could represent the position in the string of the battery module.
  • This is effectively equivalent to assigning an (x, y) coordinate to each battery in the array, and consequently can be extended indefinitely to map arrays of arbitrary size.
  • each battery module could be provided with two DIP switches, one for the x coordinate (e.g. string number), and one for the / coordinate (e.g. position in string).
  • mapping the array in this way does not require that the battery modules are actually arranged in a rectilinear manner in physical space. It simply means that different strings may be counted using one variable (e.g. x), while position in the string may be counted using another variable (e.g. y).
  • x e.g. x
  • y e.g. y
  • Such a system allows for an easy determination as to whether any two battery modules are in series with one another or not, in this example by comparing their x-coordi nates.
  • battery modules in a string may be labelled sequentially in the order that they are determined to be in a particular string.
  • swapping entire strings with one another results in an electrically equivalent circuit, so in this example the x-coordinate of a particular string may not correlate with the physical location of that string.
  • strings may be labelled sequentially in the order that they are discovered to be an independent string.
  • each position in the grid of (x, y) coordinates formed in this way can comprise at most one battery module
  • the (x, y) position of any given battery module can serve as a unique identifier for use in the method illustrated in Figure 3.
  • the master controller could be determined by the following rules:
  • the present disclosure provides a method for the array to determine the arrangement of the battery modules which make up the array.
  • the first step 560 is that the master controller (which may be a controller which is part of a battery module, or a dedicated controller, for example) selects a battery module in the array, and decouples the battery module from the array. This may be achieved, for example, by communicating with the selected module (e.g. via a bus), and sending a request to the selected battery to decouple. Upon receiving such a request, the selected battery module responds by decoupling itself from the array. In this context, by decoupling, what is meant is that the battery module breaks the connection between itself and the rest of the array, e.g. by activating a circuit breaker or electronic switch.
  • the second step 562 in Figure 5 comprises the master controller receiving a determination reading from each of the battery modules in the array. As is described in more detail below, this may be a current reading or a voltage reading, or indeed any reading which will allow the master controller to determine the arrangement of the modules in the array.
  • the final step 564 in Figure 5 is to determine the arrangement of one or more modules in the array, based on the readings taken in step 562. This determination may optionally be made by comparing the readings received in step 562 with earlier values, or it may be based solely on the readings themselves. These steps may be repeated as often as necessary to determine the position of each battery module in the array, or at least to determine which battery modules in the array are connected in series in a single string.
  • Figure 6 provides an example of the steps which may occur when current measurements are used to determine the arrangement of the battery modules in the array. This method relies on the fact that battery modules connected in series with one another will all register zero current if any one of them is decoupled. This effect is similar to that seen in fairy lights, which are traditionally wired together in series; when one bulb breaks, the whole string of lights goes out, since no current can flow.
  • the first step 670 in Figure 6 is once again to select and decouple a battery module from the array, similar to the situation described in Figure 5.
  • the next step 672 in Figure 6 is to receive a current measurement from each battery module in the array.
  • any readings of zero are determined to be received from battery modules which are in series with the selected battery module.
  • any non-zero current readings [Rsijreceived from battery modules are determined to belong to battery modules which are not in series with the selected battery module. That is to say, any non-zero readings must belong to battery modules which are in parallel with the selected battery module (or in a different string).
  • Each non-zero reading may come from battery modules which are in series with each other in a parallel string, or they may come from battery modules which are arranged in a plurality of other strings.
  • the process can be repeated by selecting a second battery module, and repeating the steps. This can be performed as a check by selecting as a second module one which was previously determined to be in series with the first module, or the second module may be one which was determined to be in parallel with the originally selected module, in order to determine which modules are connected in series with the second module. In this way, repeating the steps allows for the position of each module in the array to be mapped out. In order to ensure that the location of every module is determined, the process may be repeated once for each module in the array.
  • the process can be thought of as a two stage process.
  • the first stage determines how many strings there are in the arrangement of the array, and the second determines which of these are connected in series with one another.
  • Figure 7 jRS2 illustrates a method for carrying out the first stage of the method.
  • the first step 670 is to set a counter, n to a value of 1. This counter is used to determine the number of strings in the array. It is initialised at 1 , because as will become clear below, the method involves incrementing n until the number of strings has been determined. Due to the details of the method, the number of strings determined by the method could be too high unless n is initialised at 1.
  • step 674 a measurement is made of the total voltage output, V tot , from the array. If this voltage is zero, then the module(s) which has been disconnected has completely broken the circuit. In general if n modules have been decoupled to achieve this, then the number of parallel strings in the array must be n or less. For example, when there is only one string in the array, then decoupling any module in the array will cause the total output voltage, V tot of the array to drop to zero, since any decoupling any module will break the circuit. Clearly, however, decoupling a second, third, fourth, etc. module will not change this situation, and V tot will remain zero.
  • V to t is determined to be zero, then the number of strings in the array is determined to be n at step 676.
  • step 678 a determination as to whether every combination of n modules has been tested is made.
  • the method reverts to step 672, and a new combination of n modules is selected, and the process repeats.
  • n is incremented by one, and the process is repeated using the new value of n until a combination of modules is found which causes V to t to be zero, at which point the current value of n is determined to be the number of strings in the array, and the process finishes.
  • the process may include measuring the total output voltage prior to initiating the method described above, and shown in Figure 6.
  • the total output voltage is zero before the method starts, then it will not be possible to determine the number of strings as described above. In this case, the method will not be run, and instead an error message can be issued.
  • Figure 7 there is shown a further method of using the information determined in the method of Figure 6 to further determine which modules are connected to one another in series in strings. The method is based on the idea described above that a single string will not output any voltage if any one of the modules in that string is decoupled.
  • the method of Figure 7 begins at step 780, in which a known combination of n modules which when decoupled results in the total output of the array, V to t, to be zero. Such a combination will be known, for example, if the method of Figure 6 has been carried out, as it will be the final combination selected at step 672.
  • step 781 selects a module from the known combination of modules. This module will be used for swapping purposes.
  • step 782 the selected module (the first module) is recoupled, while a second module, which was not part of the original known set of modules is decoupled.
  • V to t a determination is made as to whether V to t, is zero. If it is, then decoupling the second module is electrically equivalent to decoupling the first module. The only way for this to be true is if the first and second modules are electrically connected together in series. That is to say, they are part of the same string. In the event that V to t, is zero, therefore, a determination is made that the first and second modules are coupled together in series at step 784. On the other hand, if V to t, is not zero, then decoupling the second module is not electrically equivalent to decoupling the first module. The only way for this to be true is if the first and second modules are electrically connected together in parallel. That is to say, they are part of different strings. In the event that V to t, is not zero, therefore, a determination is made that the first and second modules are not coupled together in series at step 785.
  • step 786 a determination is made as to whether every second module has been tested in this way. That is to say, whether each module that was not part of the original set of n modules known to result in the total output of the array, V tot , to be zero combination when decoupled together, has been tested to determine which modules it is equivalent to. If this is not the case, and there are other second modules to be tested, then the process returns to step 782, and using the same first module, repeats the process, selecting a different second module, which is then categorised as described above, based on whether decoupling the second module is electrically equivalent to decoupling the first module.
  • step 786 determines whether all first modules have been tested in this way. If they have, then the method ends, because necessarily each module has been tested, and therefore the array has been mapped out in full.
  • step 781 the process reverts back to step 781 , and selects a new first module, and the process repeats as described above, using the newly selected first module as a basis for swapping.
  • determining the electrical equivalence of decoupling pairs of first and second modules may be performed in any order, as long as the method continues until all modules have been determined to be part of one of the strings.
  • each module can be mapped to a string before the process reaches the end at step 788.
  • there may be a step which detects that the array has been fully mapped, and ends the process at that point.
  • Figure 890 there is shown a method for error detection.
  • the master controller may issue a charging demand to a charging unit attached to the array. This is step 890 in Figure 8.
  • a charging demand typically specifies a charging current, and a charging voltage. If the master controller is aware of the layout of the array, it can determine the voltage based on the number of modules in each string, and it can determine the current based on the number of strings.
  • the specific design of the modules, including the number of cells and type of cells it comprises will also play a part in determining how much voltage and current is required. In short, the purpose of selecting a specific voltage and current combination is that each module receives a sufficient voltage and current to charge it. In practice, while higher currents result in faster charging, there are safety limits which mean that currents may be limited.
  • the controller is aware of these limits for the modules in the array, and selects a charging current for the array as a whole based on the maximum allowable charging current, and its knowledge of the arrangement of the modules in the array. For example, when there are n strings in the array, the current is split between them, and each receives 1/n of the total current. Therefore, two arrays comprising the same number of modules may have vastly different maximum charging currents, due to the modules being electrically connected in different ways between the two arrays.
  • the total current demanded from the charging unit is calculated by the controller so that the current flowing through the battery module with the lowest maximum safe charging current is at that maximum value. Similarly, the total voltage supplied will be divided between each battery module in a string which may be viewed as a potential divider.
  • the controller can calculate the supplied voltage in order to make a demand by taking the arrangement of the array into account, and selecting a voltage that means that the battery module with the lowest maximum safe voltage has that maximum safe voltage across it.
  • a value of voltage and/or current calculated in step 890 is compared with a measured value.
  • the controller has calculated the charging demand based on its knowledge of the arrangement of the array and the operating parameters of the battery modules, the measured value and the calculated value should match. In the event that they do not match, this is indicative of an error. Therefore in step 894, when the measured value and the calculated value do not match, a determination is made that an error has occurred.
  • This error may be the result of one of several problems with the array. For example, it is possible that although a battery module is electrically connected to the array, it may not be in communications contact with the master controller, for example because the communications link has not correctly connected to a communications bus. Therefore, while it will charge and discharge along with the other battery modules in the array, the master controller will not know about the battery module, and will not account for it when making a charging demand. This in turn means that when the current and/or voltage is measured and compared with the calculated value, the measured value will be lower than the calculated value, as there is an extra module being charged.
  • the methods for determining an arrangement of the modules in the array can further include detecting this type of error.
  • Another possible source of error could be if the current and/or measurement is itself faulty.
  • the master controller could determine the expected current and/or voltage at several points in the array, and compare it with measurements.
  • the current in each string should be equal, so if one reading in a string is significantly different from the others, this could be an indication that there is a fault with the measurement apparatus of that battery module.
  • the voltage across an entire string should be equal for all strings, and any string measuring a significantly different voltage to the others (as determined by summing the voltages across each module in a given string) could be an indication of an error in the voltage measurement of a particular battery module in that string.
  • the controller may be further configured to alert a user to the error. In particular, it may further provide an indication of the type of error and the likely cause, for example, if the measured readings are lower than the calculated values, then the controller may propose that one or more battery modules have not made a communications link correctly, and may suggest to a user that checking the communications connections could solve the problem.
  • the controller may further send a message to the charging unit to stop the charging process. This is a safety feature to prevent unsafe charging from occurring.
  • the master controller may simply send a network message with a revised charging demand to the charging unit, to bring the measured values closer to the maximum safe values for the array.
  • the processes of Figures 5, 6, 7 or 8 may be repeated at selected intervals, in order to ensure that an accurate and up to date arrangement of the battery modules of the array is available for use in all calculations.
  • one or more of the controllers of the array may be configured to detect the addition or removal of a battery to/from the array, and to request that the arrangement be determined again (or simply trigger the determination process itself).
  • the process could be carried out periodically at regular intervals or on detection of a shut down or switch on of the array.
  • the detection process may be carried out in addition to some of the other features described herein.
  • the master controller may be selected according to the self-arbitration methods described above.
  • the battery modules may be provided with additional location information, as described above in relation to DIP switches, to allow a precise physical location of the battery module in the array to be supplied to a user, in the event that a fault is detected, and repair, replacement or other attention is required by a user in relation to a specific battery module of the array.
  • the selection of battery modules may be performed in a similar way to the selection of a master controller. That is by considering unique identifiers associated with each battery module or a controller therein.
  • the first battery module to be selected may then be, for example, the battery number with the numerically lowest unique identifier, e.g. serial number.
  • FIG 9 there is shown a system 930 for mounting a plurality of battery modules.
  • the system comprises a series of bays 932, which are shaped and sized to accommodate the battery modules described herein.
  • connectors for the battery modules may be provided (not shown), which allow the battery modules to connect to battery modules in adjacent bays.
  • the mounting system may include a controller to perform the methods set out above. In this case the controller for the system may be chosen to be a master controller by default.
  • programmable logic also include programmable processors, programmable digital logic (e.g., a field programmable gate array (FPGA), an erasable programmable read only memory (EPROM), an electrically erasable programmable read only memory (EEPROM)), an application specific integrated circuit, ASIC, or any other kind of digital logic, software, code, electronic instructions, flash memory, optical disks, CD-ROMs, DVD ROMs, magnetic or optical cards, other types of machine-readable mediums suitable for storing electronic instructions, such as software and firmware, or any suitable combination thereof.
  • FPGA field programmable gate array
  • EPROM erasable programmable read only memory
  • EEPROM electrically erasable programmable read only memory
  • ASIC application specific integrated circuit
  • one or more memory elements can store data and/or program instructions used to implement the operations described herein.
  • Embodiments of the disclosure provide tangible, non-transitory storage media comprising program instructions operable to program a processor to perform any one or more of the methods described and/or claimed herein and/or to provide data processing apparatus as described and/or claimed herein.

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Abstract

L'invention concerne un contrôleur de module de batteries configuré pour coopérer avec d'autres contrôleurs similaires de modules de batteries pour constituer un réseau à organisation autonome de modules de batteries. Chaque module de batteries comprend au moins un accumulateur d'énergie. Le contrôleur de module de batteries comprend un identifiant unique et est configuré (i) pour envoyer un message de réseau comprenant son identifiant unique ; (ii) pour recevoir un ou plusieurs messages de réseau comprenant chacun un identifiant unique d'un autre contrôleur respectif d'un module de batteries dans le réseau ; et (iii) pour identifier, sur la base du ou des messages reçus, un des contrôleurs du réseau en tant que contrôleur maître.
PCT/GB2017/051488 2016-05-26 2017-05-25 Procédés et appareil d'accumulation d'énergie Ceased WO2017203265A1 (fr)

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CN114361561B (zh) * 2021-12-31 2024-03-19 杭州鹏成新能源科技有限公司 一种新型可选择组合并成组的电池包成组系统及成组方法
WO2023144137A1 (fr) * 2022-01-31 2023-08-03 Robert Bosch Gmbh Unité de commande permettant de gérer un groupe de blocs-batteries dans un système et procédé associé
WO2024158502A1 (fr) * 2023-01-25 2024-08-02 Caterpillar Inc. Détection d'un mauvais assemblage de bloc-batterie

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GB2550881B (en) 2019-05-29
GB2554789A (en) 2018-04-11

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