Patent Application
20240288501
The present disclosure relates to the field of battery technology and energy cells. In particular, disclosed embodiments relate to methods, systems, and devices for monitoring a state of a battery system, its battery cells, or both and detecting faults arising at the battery system, battery cells, or both.
Battery systems including a plurality of battery cells are used in a wide range of modern electric power applications. For example, battery systems are used in industrial applications (such as transportation, e.g., powering electric vehicles and power grids) and commercial applications (e.g., powering electronic devices, including laptop computers, mobile devices, medical devices, etc.). Given the relatively high-power demands of such applications, a battery system often includes a plurality of battery cells coupled together in series, parallel, or mixture of both, to achieve a required power output. Battery cells may be coupled together to form a battery pack, where the battery system may include one or more battery packs.
Some battery cells contain a flammable electrolyte, and thus can be dangerous under certain conditions. For example, battery cells may become damaged if they are overcharged above a certain voltage or if they exceed a certain temperature. If then further overcharged, such battery cells may go into thermal runaway. Battery cells may also become damaged if discharged below a certain voltage.
Also, the lifetime of battery cells can be reduced if they are discharged at a too high current or if they are charged too quickly.
Safe use of a battery system therefore requires operating the battery system within its Safe Operating Area (SOA). The SOA is often defined as voltage, current, and temperature conditions within which the cells of the battery system are expected to operate without becoming damaged or creating a hazard to the battery system's operator.
To facilitate effective use of a battery system, a lesser constraint than the SOA, i.e., a Normal Operating Area (NOA), may also be defined and enforced at the battery system, e.g., using corresponding voltage, current, and temperature conditions defined for the battery cells. Breaching the NOA is expected to reduce capacity of cells in the battery system, lifetime of cells in the battery system, or both, overtime.
In multi-cell configurations, unevenness of charge and discharge that can arise between cells and battery packs of the battery system may present an additional challenge to the safe and effective use of the battery system.
It is common to connect a battery system to a battery management system (BMS) for monitoring and managing performance of the battery system to ensure its safe and effective operation. BMS measures properties of battery cells in the battery system (e.g., voltage, current, and temperature) and evaluates the measurements to determine the state of the battery system and identify faulty operation of the battery system before a catastrophic fault occurs. For example, the BMS may evaluate the measurements to confirm that the battery cells operate within the SOA using an analytical model of the battery system defined based on manufacturing specification of the battery cells.
BMS may also calculate various secondary data, control environment of the battery system, and balance the battery system.
Each battery pack 1101, 1102. 1103 respectively has measuring device (MD) 1201, 1202, 1203. Each MDs 1201, 1202. 1203 includes an array of sensors configured to measure properties (may also be referenced as performance characteristics) of respective battery pack 1101, 1102. 1103, for example, voltage, current, and temperature of battery cells 115. In the example of
Battery system 100 also includes BMS 130 connected to battery packs 1101, 1102. 1103. In battery system 100, BMS 130 is a master device, while MDs 1201, 1202, 1203 are slave devices. MDs 1201, 1202. 1203 are coupled in series (daisy chained) forming communication channel 125 terminating at BMS 130.
As shown in
With reference to
While in OFF mode 214, BMS 130 and MDs 120 are inactive. BMS 130 does not communicate with MDs 120, receive, or evaluate any measurements, or report to external system 240.
As shown in
With reference to
While in OFF mode 214, BMS 130 is inactive, and thus does not request, receive, or evaluate any measurements of MDs 120. Therefore, if one or more cells 115 develop a fault or experience condition(s) that may result in a fault, e.g., in a delayed fault, BMS 130 may not learn of such a fault or condition while BMS 130 is in OFF mode 214. Further, as MDs 120 do not obtain any measurements while BMS 130 is in OFF mode 214, BMS 130 may not learn of faults, or conditions that could lead to a fault, that developed during OFF mode 214, even after BMS 130 transitions into ON mode 212. Consequently, some faults and conditions leading to faults may remain undetected for prolonged periods of time or not detected at all.
In accordance with an aspect of the present disclosure, there is provided a method for monitoring a cell group by a cell monitoring device, CMD, the cell group comprising one or more battery cells, the method comprising: receiving, by the CMD of the cell group, from at least one sensor configured to measure one or more properties of the cell group, at least one measurement obtained by the at least one sensor, the CMD comprising at least one cell model of the cell group configured for the cell group; processing the received at least one measurement by the CMD using a corresponding cell model of the cell group to determine whether the cell group experienced a fault; in response to determining a first fault at the cell group, storing in memory of the CMD, a fault indicator, indicating that the cell group experienced the first fault, and fault data related to the first fault, the fault data comprising a timestamp generated when the first fault was determined by the CMD; retrieving, from the memory of the CMD, one or more fault indicators and corresponding fault data, including the fault indicator and the fault data related to the first fault, each fault indicator indicating that the cell group experienced a corresponding fault; and communicating, by the CMD to a battery management system, BMS, configured to manage a battery comprising the cell group, or to an external device configured to collect data about the battery comprising the cell group, the retrieved one or more fault indicators and corresponding fault data.
For each determined fault, the related fault data may comprise at least one of: one or more sensor measurements the CMD used to determine the fault, or one or more derived measurements the CMD used to detect the fault.
For each determined fault, the fault indicator may identify the fault.
The method may comprise determining, based on the received at least one measurement, a severity level of the first fault, the severity level being one of an immediate hazard, a delayed hazard, or a degradation hazard.
Determining the severity level of the first fault may comprise upgrading the severity level of the first fault from the delayed hazard to an immediate hazard or from the degradation hazard to an immediate hazard when the CMD determines the first fault within a predefined time period after determining one or more other faults at the cell group.
The fault indicator of the first fault may identify the severity level of the first fault.
The method may comprise repeating the receiving and processing steps by the CMD when no fault is determined at the cell group.
The method may comprise repeating the receiving, processing, and storing steps by the CMD to detect a plurality of faults.
The receiving, processing, and storing steps may be repeated by the CMD independent of the BMS or the external device.
The receiving and processing steps may be repeated with a varied frequency depending on whether the CMD is in a first mode or a second mode, and/or depending on a type of at least one measurement.
Determining the first fault may comprise: processing a sequence of measurements obtained by the at least one sensor at the cell group and determining by the CMD relative to a corresponding cell model of the cell group that the cell group experienced a fault based on a predefined number of measurements in the sequence.
Communicating to the BMS may comprise, in response to determining the first fault, transmitting an alert by the CMD to the BMS; and transmitting a status update of the cell group from the CMD to the BMS. The status update may comprise the one or more fault indicators and the related fault data.
The status update may be transmitted in response to a request received from the BMS.
The alert may be a signal configured to cause the BMS to transition from one mode to another mode.
The alert may be transmitted by the CMD to the BMS when the detected first fault is determined to have a severity level of an immediate hazard.
Communicating to the BMS may comprise transmitting a status update of the cell group from the CMD to the BMS. The status update may comprise the one or more fault indicators and the related fault data.
The status update may be transmitted by the CMD to the BMS periodically, at a prescheduled time, or in response to a request received from the BMS.
The status update may comprise the one or more fault indicators and the related fault data concerning one of: all faults determined by the CMD at the cell group since a previous status update transmitted by the CMD to the BMS, all faults determined by the CMD at the cell group during a predefined time range, or all faults detected by the CMD. All relevant faults may be identified based on the timestamps included in the respective fault data.
The first fault may be an operational fault. The operational fault may be determined by the CMD when performance of the cell group is determined to fall outside of a safe operating area defined by predetermined safe operational limits or outside of a normal operating area defined by predetermined normal operational limits, wherein the safe and normal operational limits correspond to the obtained measurements and defined by the at least one cell model of the cell group.
The operational fault may be determined when the at least one measurement obtained at the cell group meets at least one of the following conditions: a current flowing through the cell group exceeds a maximum charge current predefined for the one or more battery cells in the cell group, the current flowing through the cell group exceeds a maximum discharge current predefined for the one or more battery cells in the cell group, a temperature taken at the cell group is below a minimum operational temperature predefined for the one or more battery cells in the cell group, the temperature taken at the cell group exceeds a maximum operational temperature predefined for the one or more battery cells in the cell group, a cell terminal voltage of the one or more battery cells in the cell group exceeds a maximum operational voltage predefined for the one or more battery cells in the cell group, or the cell terminal voltage of the one or more battery cells in the cell group is below a minimum operational voltage predefined for the one or more battery cells in the cell group.
The first fault may be a behavioural fault. The behavioural fault may be determined when performance of the cell group deviates from expected performance of the cell group by a deviation greater than a predefined threshold. The expected performance of the cell group may be defined by the at least one cell model, and/or performance of one or more neighbouring cell groups determined based on measurements obtained by sensors at the one or more neighbouring cell groups, the obtained measurement received by the CMD from respective one or more CMDs of the one or more neighbouring cell groups.
The behavioural fault may be determined when the at least one measurement obtained at the cell group meets at least one of the following conditions: a rate of change of temperature at the cell group is greater or less than a thermo-electrical model of the cell group for a known stimulus and a current state of the cell group, or a rate of change of voltage at the cell group is greater or less than a thermo-electrical model of the cell group for a known stimulus and the current state of the cell group.
The method may comprise receiving, by the CMD from the one or more neighbouring CMDs, measurements obtained respectively by the sensors at the one or more neighbouring cell groups and corresponding to the measurements obtained at the cell group.
The behavioural fault may be determined when a change, or a rate of change, determined in one or more measurements obtained at the cell group over a period of time deviates from a change, or a rate of change respectively, detected in corresponding one or more measurements obtained at the one or more neighbouring cell groups over the same period of time by a deviation greater than a predefined threshold when the cell group and one or more neighbouring cell groups are exposed to the same stimulus.
The at least one sensor may comprise one or more of: a sensor adjacent to the cell group, a sensor located at the cell group, a sensor located within the cell group, a sensor incorporated with the cell group, a sensor located on one or more battery cells of the cell group, or a sensor located incorporated with one or more battery cells of the cell group.
The at least one sensor may comprise a sensor configured to measure an electric, chemical, or physical property of a battery cell in in the cell group and a different sensor configured to measure an electric, chemical, or physical property of the cell group.
The at least one sensor may comprise one or more of: a voltage sensor for measuring voltage at the cell group or at a battery cell in the cell group, an external temperature sensor for measuring temperature external to the cell group, a temperature sensor integrated with the CMD for measuring temperature at the cell group, a temperature sensor integrated with a battery cell in the cell group for measuring temperature at the battery cell, a temperature sensor integrated within a battery cell in the cell group for measuring temperature within the battery cell, a gas pressure sensor integrated within a battery cell in the cell group for measuring gas pressure within the battery cell, a force sensor integrated with or within a battery cell in the cell group for measuring a force exerted by the battery cell on an external surface, a strain gauge integrated with or within a battery cell in the cell group for measuring deflection of a battery cell enclosure of the cell caused by a change of internal pressure, a humidity sensor for measuring humidity at the cell group or at a battery cell in the cell group, a chemical sensor for measuring pre-determined chemical by-products of cell damage, or a current sensor for measuring current flowing through the cell group or through a battery cell in the cell group.
The method may comprise processing the one or more fault indicators and corresponding fault data retrieved from the memory of the CMD prior communicating the one or more fault indicators and corresponding fault data to the BMS or the external device, wherein processing comprises one or more of: compressing the one or more fault indicators and corresponding fault data for transmission to the BMS or external device, or encrypting the one or more fault indicators and corresponding fault data for transmission to the BMS or external device.
In accordance with another aspect of the disclosure, there is provided a storage medium (e.g., a non-transitory storage medium) storing computer-executable instructions, which when executed on a processor configure the processor to carry out any of the afore-mentioned methods.
In accordance with a further aspect of the disclosure, there is provided a computer program product comprising computer-executable instructions which, when executed on a processor, configure the processor to carry out any of the afore-mentioned methods.
In accordance with yet another aspect of the present disclosure, there is provided a circuitry configured to execute functions for causing a cell monitoring device, CMD, to perform any of the afore-mentioned methods.
In accordance with a further aspect of the present disclosure, there is provided a cell monitoring device, CMD, configured for assembly with a cell group comprising one or more battery cells and comprising the afore-mentioned circuitry, a memory for storing fault data related to faults determined by the CMD at the cell group and a sensor subsystem for controlling at least one sensor.
The CMD may be configured to operate in a first mode and a second mode, wherein the CMD may be configured to receive and process measurements obtained by the at least one sensor at the cell group to determine whether the cell group experienced a fault less frequently while operating in the first mode than while operating in the second mode.
In accordance with an aspect of the present disclosure, there is provided a method for monitoring a battery by a battery management system, BMS. The battery comprises a plurality of cell groups, each cell group comprising one or more battery cells and a corresponding cell monitoring device, CMD. The method comprises the BMS receiving a fault indicator and fault data from a CMD (referenced as a “first CMD”) of a cell group (referenced as a “first cell group”) in the plurality of cell groups. The fault indicator indicates that the first CMD determined a fault at the first cell group based on one or more measurements of cell properties obtained at one or more cells in the first cell group by at least one sensor associated with the first CMD. The fault data relates to the determined fault and comprises a timestamp indicating when the first CMD determined the fault. The method further comprises the BMS processing the received fault indicator and fault data to determine an action responsive to the fault.
The method may comprise: the BMS receiving a command to connect the battery to a power source and the BMS checking a status of the battery prior to connecting the battery to the power source. Checking the status of the battery comprises the steps of receiving and processing the fault indicator and the fault data. The method may further include rejecting the command to connect the battery to the power source responsive to a result of processing the received fault indicator and fault data.
The method may also include issuing an alert that the battery is experiencing a fault condition responsive to a result of processing the received fault indicator and fault data.
The fault data may also comprise at least one measurement used by the first CMD to determine the fault. The at least one measurement may comprise one or more of: a measurement obtained at the first cell group, or a measurement derived based on one more measurements obtained at the first cell group, or a combination thereof.
The fault indicator may indicate one or more of: the fault or a severity level of the fault, the severity level being one of an immediate hazard, a delayed hazard, or a degradation hazard.
Processing the received fault indicator and fault data may comprise storing, at the BMS, the fault indicator and the related fault data received from the first CMD.
The method may comprise: receiving, from an external system, a request for a status update of the battery; and transmitting the status update of the battery to the external system, the status update comprising the fault indicator and the related fault data stored at the BMS.
Processing the received fault indicator and fault data may comprise: using one or more cell models with the received fault data to confirm that the first cell group experienced the fault, the one or more models stored at the BMS and corresponding to cells of the first cell group.
Processing the received fault indicator and fault data may comprise: receiving a status update on another cell group (referenced as a “second cell group”) in the plurality of cell groups, from a CMD of the second cell group (referenced as a “second CMD”), the status update comprising at least one of: one or more measurements of one or more cell properties of one or more cells in the second cell group obtained by at least one sensor of the second CMD, or fault data related to one or more faults determined by the second CMD at the second cell group, the fault data comprising one or more timestamps indicating when the second CMD respectively determined the one or more faults; and comparing the fault data received from the first CMD with data included in the status update received from the second CMD to confirm that first cell group experienced the fault.
The method may comprise transmitting, upon receiving the fault indicator and fault data from the first CMD, a status request to the second CMD. The status update on the second cell group may be received by the BMS in response to the status request.
The second cell group may comprise one or more cells adjacent to the first cell group.
The method may comprise repeating the receiving and comparing steps for each cell group of the plurality of cell groups.
The BMS may receive the fault indicator indicating that the first CMD determined that first cell group experienced the fault and the related fault data from the first CMD of the first cell group as a part of a status update provided by the first CMD to the BMS. The status update may be received by the BMS periodically, at a prescheduled time, or in response to a status update request sent by the BMS to the first CMD.
The status update by the first CMD may comprise one or more fault indicators and related fault data concerning one or more of: all faults determined by the first CMD at the first cell group since a previous status update received by the BMS from the first CMD, all faults determined by the first CMD at the first cell group during a predefined time period, all faults determined by the first CMD at the first cell group, or one or more faults determined by the first CMD at the first cell group while the BMS was powered off, inactive, or out of communication with the first CMD.
The BMS could be in a sleep mode prior to receiving the fault indicator and the related fault data from the first CMD. The method may comprise: receiving, by the BMS in the sleep mode, an alert signal from the first CMD indicating that the first CMD detected the fault; and responsive to the alert signal, transitioning the BMS from the sleep mode to an active mode to process the fault indicator and related fault data. The fault determined by the first CMD may be classified by the first CMD as an immediate hazard.
The method may comprise, responsive to the alert signal, transmitting a status update request from the BMS to the first CMD, wherein the fault indicator and related fault data may be received from the first CMD responsive to the status update request.
The measurements obtained at the first cell group and received by the BMS as the fault data may comprise one or more of: a voltage detected at the first cell group, a temperature detected externally to the cell group, a temperature at the first cell group, a temperature at a cell or within the cell of the first cell group, a gas pressure within a cell of the first cell group, a force exerted by a cell of the first cell group on an external surface of the cell, a deflection of a cell enclosure of a cell in the first cell group caused by a change of internal pressure, a humidity level at the first cell group or at a cell in the first cell group, a predetermined chemical indicative of cell damage, or a current flowing through the first cell group or through a cell in the first cell group.
The fault determined at the first cell group may be an operational fault or a behavioural fault.
The operational fault may be determined when performance of the first cell group is determined to fall outside of a safe operating area defined by predetermined safe operational limits or outside of a normal operating area defined by predetermined normal operational limits. The safe and normal operational limits correspond to the measurements obtained at the first cell group and may be defined by a cell model corresponding to the first cell group.
The behavioural fault may be determined when performance of the first cell group deviates from expected performance of the first cell group by a deviation greater than a predefined threshold, the expected performance of the first cell group being defined by at least one of: a cell model corresponding to the first cell group or performance of one or more neighbouring cell groups in the plurality of cell groups determined based on measurements obtained by local sensors at the one or more neighbouring cell groups.
The operational fault may be determined when the measurements obtained at the first cell group meet one or more of conditions: a current flowing through the first cell group exceeds a maximum charge current predefined for the one or more battery cells in the first cell group, a current flowing through the first cell group exceeds a maximum discharge current predefined for the one or more battery cells in the first cell group, a temperature taken at the cell group is below a minimum operational temperature predefined for the one or more battery cells in the cell group, the temperature taken at the cell group exceeds a maximum operational temperature predefined for the one or more battery cells in the first cell group, a cell terminal voltage of the one or more battery cells in the cell group exceeds a maximum operational voltage predefined for the one or more battery cells in the cell group, the cell terminal voltage of the one or more battery cells in the cell group is below a minimum operational voltage predefined for the one or more battery cells in the cell group, a cell pressure of the one or more battery cells in the cell group exceeds a maximum operational pressure predefined for the one or more battery cells in the cell group, or a cell pressure of the one or more battery cells in the cell group is below a minimum operational pressure predefined for the one or more battery cells in the cell group.
The behavioural fault may be determined when the measurements obtained at the first cell group meet at least one of the following conditions: a rate of change of temperature at the first cell group is greater or less than a thermo-electrical model of the first cell group for a known stimulus and a current state of the first cell group, or a rate of change of pressure at the first cell group is greater or less than a thermo-electrical model of the first cell group for a known stimulus and a current state of the first cell group, ora rate of change of voltage at the first cell group is greater or less than a thermo-electrical model of the first cell group for a known stimulus and a current state of the first cell group.
The method may comprise: the BMS receiving measurements obtained at one or more cell groups neighbouring the first group by corresponding one or more neighbouring CMDs, where the measurements obtained at the one more neighbouring cell groups correspond to the measurements obtained at the first cell group and are received from the one or more neighbouring CMDs.
The behavioural fault may be determined when a change, or a rate of change, determined in one or more measurements obtained at the first cell group over a period of time deviates from a change, or a rate of change, respectively determined in corresponding one or more measurements obtained at the one or more neighbouring cell groups over the same period of time by a deviation greater than a corresponding threshold, while the first cell group and the one or more neighbouring cell groups are exposed to the same stimulus.
In accordance with another aspect of the present disclosure, there is provided a circuitry configured to execute functions for causing a BMS to perform any of the afore-mentioned methods.
In accordance with yet a further aspect of the disclosure, there is provided a storage medium (e.g., a non-transitory storage medium) storing computer-executable instructions, which when executed on a processor configure the processor to carry out any of the afore-mentioned methods.
In accordance with yet a further aspect of the disclosure, there is provided a computer program product comprising computer-executable instructions which, when executed on a processor, configure the processor to carry out any of the afore-mentioned methods.
The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate disclosed embodiments and, together with the description, serve to explain the disclosed embodiments. In the drawings:
In the following description, certain aspects and embodiments of the present disclosure will become evident. It should be understood that the disclosure, in its broadest sense, could be practiced without having one or more features of these aspects and embodiments. It should also be understood that these aspects and embodiments are merely exemplary.
The following detailed description refers to the accompanying drawings. Wherever possible, the same or similar reference numbers are used in the drawings and the following description to refer to the same or similar parts or components. While several illustrative embodiments and aspects are described herein, modifications, adaptations and other implementations are possible. For example, substitutions, additions, or modifications may be made to the parts and components illustrated in the drawings, and the illustrative methods described herein may be modified by substituting, reordering, removing, or adding steps to the disclosed methods. Accordingly, the following detailed description is not limited to the disclosed embodiments, aspects, and examples. Instead, the proper scope is defined by the appended claims.
In known battery systems, such as the battery systems discussed with reference to
For example, a sudden spike in temperature at cell(s) in a battery pack, although potentially detrimental to the health of the respective battery pack and battery system as a whole and indicating a fault, may not be detected if the spike occurs while the BMS is in OFF mode 214. A cell or battery pack may reach the temperatures outside its SOA while the BMS is in OFF mode 214, and subsequently cool down before the BMS is switched ON again. Such a fault may potentially provoke a catastrophic chain reaction.
Early identification of such faults would enable issuance of an early warning to the battery operator (e.g., a vehicle driver), facilitate implementation of prompt remedial action(s) that could prevent the faults from rising to a catastrophic level, or both. Using the above example, when a sudden spike temperature at a particular cell or battery pack is detected as it happens or shortly after, preventing charging of the battery system and preventing the start of the vehicle would reduce or prevent propagation of the fault through the battery system, including rising to a catastrophic level (e.g., fire hazard). Replacing the respective cell or battery pack, rather than the entire battery system that is otherwise is functional and operating normally, may then be sufficient to remedy the detected fault.
At least some embodiments of the present disclosure address one or more shortcomings of the prior art systems discussed above with reference to
The present disclosure describes methods, systems, and devices for monitoring the state of cells forming a battery system and of the battery system itself and detecting faults arising in such battery cells. The present disclosure provides for a system that includes a battery comprising cell groups, each cell group comprises one or more cells. The system also comprises cell monitoring devices (CMDs) respectively associated with corresponding cell groups, at least one CMD per cell group. Each CMD is operable to measure properties of cells in the respective cell group, using CMD's sensor system, and processes and evaluate such measurements to detect potential faults at the monitored cells, independent of BMS or any external device and notwithstanding whether the CMD is connected to a BMS or is in communication with BMS. CMDs may use one or more cell models calibrated for corresponding cells to enable CMDs to detect faults based on property measurements obtained at the respective cell groups.
A CMD is operable to store data related to the obtained measurements, including any detected fault(s) locally at the CMD for subsequent retrieval, such as responsive to a status update request from BMS or an external device. For example, when the CMD detects a fault, the CMD stores a fault indicator indicating that the cell group associated with (monitored by) the CMD experienced a fault. The CMD also stores fault data related to the detected fault. The fault data at minimum includes a timestamp indicating when the CMD detected the fault. The fault data may also include any data that was relevant or led to the CMD determining the fault. The fault data thus may, for example, include measurements obtained at the cell group, derivatives of such measurements, or a combination of direct and derivative measurements that led the CMD to determine the fault.
An indicator that a CMD detected a fault is stored at the CMD with relevant timing information and available for subsequent retrieval, such as in response to a BMS performing a check on monitored cells before closing a battery system relay to connect the monitored battery system to a power source, such as a charger, or a load such as a powertrain. The BMS therefore becomes aware that a particular cell or cells experienced a fault, while the BMS was incommunicado (out of communication with the CMD), before closing the battery system relay, and thus allows for implementation of remedial measures before the fault triggers a catastrophic chain reaction, such as a thermal runaway.
By enabling and employing CMDs to monitor cell states of associated cells, independent of BMS or any other external systems, such as when a BMS is asleep or powered off, and to store relevant data, including concerning any related faults, and by making such data available for subsequent retrieval, methods and systems of this disclosure enable early identification of faults and timely communication of such faults to a respective BMS or an external system. This in turn enables issuance of an early warning to the battery operator (e.g., a vehicle driver), facilitates implementation of prompt remedial action(s) that could prevent the faults from rising to a catastrophic level, or both. For example, when a sudden spike temperature at a particular cell or battery pack is detected as it happens or shortly after, preventing charging of the battery system and preventing the start of the vehicle would reduce or prevent propagation of the fault through the battery system, including from rising to a catastrophic level (e.g., fire hazard).
CMD 400 is associated with or connected to one or more battery cells of a battery system to monitor the state of such cells, notwithstanding whether the battery system is connected to battery management system (BMS) 430 or used to operate a particular device or system, such as an electric vehicle. For example, CMD 400 can be used to monitor the state of one or more battery cells while BMS 430 is powered off or otherwise unavailable, such as while a respective battery system is in storage or being shipped, before the battery system is connected to a device or system whose operation the battery system is designed to support, or after the battery system is disconnected from the device or system whose operation the battery system is designed to support.
CMD 400 can be incorporated with a battery cell or attached, permanently or removably, to the battery cell or its components. For example, CMD can be configured for attachment to a flexible pouch of a pouch cell or to a housing of the pouch cell. Additionally or alternatively, CMD 400 can be electrically coupled to one or more terminals of a battery cell, for example to draw power to support functionality of CMD 400.
Multiple CMDs 400 are employed to monitor the status of battery cells forming a battery system. Battery cells are divided into groups, where each group has its own CMD 400. A group of cells includes one or more cells. For example, a group of cells may include a single cell, or a plurality of cells connected in parallel.
In some embodiments, CMD 400 is implemented as an application-specific integrated circuit (ASIC). CMD 400 in the form of an ASIC can be configured to be attached to a battery cell or group of cells, such as to a housing or to one or more components of a battery cell or a group of cells, or be incorporated or integrated with a battery cell or a group of cells.
Sensor system 410 measures properties related to the state of battery cells being monitored by CMD 400, such as physical characteristics of the monitored battery cells, electrical characteristics of the monitored battery cells, chemical characteristics of the monitored battery cells, environmental characteristics that influence the state of the cells, or any combination thereof. Sensor system 410 includes or is connected to a group of sensors 411 related to the monitored cells and configured to obtain measurement of different properties of such cells using sensors 411. Sensor system 410 may also include sensors configured to measure different properties of the cell group's environment.
Group of sensors 411 includes one or more voltage sensors 4141 configured to measure voltage at one or more monitored cells and one or more temperature sensors 4142 configured to measure temperature at one or more monitored cells (e.g., temperature of the one or more monitored cells, temperature of cell surface of the one or more cells, or temperature of the immediate environment of the one of more cells). Group of sensors 411 may also include one or more current sensors 4143 configured to measure current flowing in or out of one or more monitored cells or a group of cells. Group of sensors 411 may include one or more sensors 4144 configured to measure other properties of one or more monitored cells, for example, one or more pressure sensors, one or more humidity sensors, or a combination thereof.
A particular sensor 414 may be positioned: within a cell (e.g., within the cell enclosure, such as within a flexible pouch of a pouch cell), on a cell, its component, or its housing, at a cell, e.g., adjacent, or otherwise proximate to a cell or the respective CMD of the cell, or remotely to a cell, depending on what physical, electrical, chemical, or environmental properties of one or more cells that sensor 414 is configured to measure.
For example, a pressure sensor in the form of a gas pressure sensor may be integrated within the cell enclosure, to measure gas pressure within the cell enclosure. A pressure sensor in the form of a strain gauge may be positioned on a cell to monitor the deflection of the cell enclosure caused by a change in the internal pressure of the cell. A current sensor may be positioned at a monitored cell to measure current flowing in, out, or through the cell (e.g., electrically coupled to cell terminals to measure their output). A voltage sensor may be positioned at a monitored cell or a group of monitored cells to measure voltage across terminals of the monitored cell or cell group. A temperature sensor may be integrated with CMD 400 to measure temperature of an immediate environment of the cells monitored by CMD 400. Some sensors 414 may be external to both CMD 400 and cells monitored by CMD 400. For example, CMD 400 may employ a temperature sensor for measuring temperature of a surrounding environment.
Each sensor 414 may be implemented as a combination of one or more sensing elements for measuring corresponding physical, electrical, or chemical cell properties and of signal conditioning circuitry that converts the output of the one or more sensing elements into an analogue signal suitable for conversion by analogue-to-digital converter (ADC) 418. The signal conditioning circuitry can be collocated with the one or more sensing elements or located elsewhere in CMD 400, including externally to the respective cell. For example, only sensing elements can be positioned within a cell, on a cell, or at a cell, depending on what physical, electrical, chemical, or environmental properties such sensing elements are configured to measure, while respective signal conditioning circuitry can be positioned externally to the respective cell.
In some embodiments, group of sensors 411 includes one or more external sensors which are integrated with a corresponding ADC. In these embodiments, the ADC provides respective measurements in a digital form. Such measurement can be shared with FDS 420 and processor system 422 directly, bypassing ADC 418.
Sensor system 410 may also include self-diagnostic sensors 412 to provide reference measurements. By comparing reference measurements with corresponding measurements obtained by sensors 414 for a given stimulus, CMD 400 is able to determine whether measurements obtained by sensors 414 are true to the actual system operation or distorted, for example, due to internal issues with sensors 414.
Sensor system 410 also includes ADC 418 for converting the measurements obtained by sensors 412 and 414 into a digital form and a switch 416 (e.g., a multiplexer) for directing the measurements from sensors 414 to ADC 418 for conversion. ADC 418 outputs the converted measurements to FDS 420, processor system 422, or to both. In some embodiments, switch 416 is integrated into the structure of one or more ADC 418. For example, ADC 418 may have multiple inputs for receiving sensor measurements.
As shown in
Additionally or alternatively, CMD 400 may employ multiple ADC 418 to introduce redundancy within CMD 400. This in turn enhances functional safety of CMD 400, such as in the event of failure by one of ADCs 418.
FDS 420 is operable to evaluate the received measurements to determine if one or more cells monitored by CMD 400 have experienced or are experiencing a fault.
In some embodiments, FDS 420 is implemented in digital logic on an ASIC forming CMD 400. In such implementations, functionality of FDS 420 and cell models 421 are identified at the ASIC design stage.
In some embodiments, FDS 420 is implemented as a processor separate from processor system 422 with separate memory (not shown) and processing defined by firmware. In this implementation, FDS 420 may take the form of a microprocessor or an embedded processor. When FDS 420 is implemented as a separate processor, CMD 400 can be adapted to work with specific cells, or a type of cells post-design and post-manufacturing. No knowledge of cell's chemistry or type is required during design or manufacturing of CMD 400 to ensure full functionality of FDS 420. Additionally, FDS can be reprogrammed after being assembled with a cell group, for example, to modify settings in cell model(s), update cell model(s), or upload new cell model(s).
In some embodiments, a combination of hardware and software is used to implement FDS 420. In such implementations, FDS's processes can be designed using digital logic of an ASIC forming CMD 400, while parameters that would be employed by cell model(s) 421 can be programmed into locally stored tables. This programming can be implemented using different methods. For example, during the production stage or prior to CMD 400 being used with a particular cell or cell group, a metal layer mask made for that cell or cell group's chemistry can be introduced into CMD 400 to configure CMD 400 to work with the cell or cell group. Another example is to introduce one-time programmable memory (e.g., poly fuses) into CMD 400 during the production stage and program such memory with relevant tables prior to using CMD 400 with a cell or cell group. Yet another example is to load chemistry specific tables by processor system 422.
Although
FDS 420 employs one or more cell models 421 to evaluate the received measurements for presence of a fault at one or more monitored cells. Cell model 421 receives one or more measurements related to one or more monitored cells as input, evaluates such measurements to determine whether corresponding one or more cells have or are experiencing a fault, and outputs results of the evaluation.
A cell that experienced one or more faults is in a fault condition. As discussed throughout this disclosure, a BMS, such as BMS 430, or an external system, can be operable to determine whether a cell is in a fault condition based on data shared by CMD 400, such as property measurements obtained at the cell by CMD 400, and any faults determined at the cell by CMD 400.
Different cell models 421 may be operable to evaluate respectively different cell properties, different combinations of cell properties, or for different faults. For example, a cell model may be operable to evaluate whether a measurement of a corresponding cell property of a cell exceeds a SOA or a NOA for that cell.
As referenced throughout this disclosure, SOA may be defined as one or more conditions (e.g., voltage, current, temperature, pressure, or any other conditions described in this disclosure), or any combination thereof, within which cells of a battery system are expected to operate without becoming damaged or creating a hazard to the battery system's operator. Similarly, as referenced throughout this disclosure NOA, a lesser constraint than SOA, may be defined as one or more conditions (e.g., voltage, current, temperature, pressure, or any other conditions described in this disclosure), or any combination thereof, within which cells of a battery system are expected to operate without significant (above expected) reduction in capacity, lifetime, or both, overtime.
Additionally or alternatively, FDS 420 may employ one or more cell models 421 each operable to evaluate different cell properties and for different types of faults. For example, a cell model may be operable to evaluate a combination of different properties of a cell to determine whether the cell is operating within its SOA or NOA. FDS 420 may also employ a single cell model configured to determine various kinds of faults that FDS 420 is operable to detect.
In some embodiments, one or more cell models 421 are designed or defined based on manufacturing specification for the monitored cells. Additionally or alternatively, one or more cell models 421 may be defined based on measured properties of the relevant cells at the beginning of their life, such as during initial testing of the cells.
One or more cell models 421 may include one or more numerical cell models, one or more analytical cell models, one or more empirical models, or any combination thereof. One or more cell models 421 may include one or more simple models, one or more complex models, or a combination of both. A simple cell model may check inputted one or more measurements against one or more predefined limits (or thresholds) and flag a fault when the one or more measurements exceed one or more of the predefined limits, e.g., higher or below the one of the predefined limits, or outside predefined limits, or within predefined limits. A more complex cell model may first process the one or more measurements, e.g., by determining one or more derivative measurements and comparing such derivative measurements to one or more thresholds (predefined limits), and then apply filter(s), algorithm(s), or both to determine a fault. A more complex model may also, or instead, set a varying threshold for one or more cell properties (e.g., voltage) based on a measurement of another one or more cell properties (e.g., temperature).
Cell models 421 may be implemented using software, firmware, hardware, or mixture of thereof. For example, checks against thresholds or limits may be implemented in hardware, using analogue or digital comparators, while the threshold or limits themselves may be set and varied by software or firmware. Another example is a cell model designed to integrate the signal from a current sensor over time to provide a coulomb (Amp-seconds) count. The signal integration may be implemented in digital hardware, e.g., using a digital integrator, or in software, e.g., using processor's arithmetical capability.
In some embodiments, FDS 420 is operable to classify detected faults by their severity level. A severity level indicates how urgently a remedial action for addressing the detected fault should be implemented.
FDS 420 may, for example, use three severity levels to classify faults. The first (highest) severity level indicates a fault representing an immediate hazard. Immediate hazard faults include those faults that require an immediate or urgent remedial action. For example, FDS 420 may classify a fault detected based on temperature measurements taken at one or more cells, a rate at which the temperature at the one or more cells has increased, or both, as an immediate hazard fault if the temperature measurements, the rate of temperature increase, or both indicate an imminent thermal event (i.e., fire).
The second (middle) severity level indicates a fault representing a delayed hazard. Delayed hazard faults include those faults that, although result in damage to one or more monitored cells, do not present an immediate danger. For example, FDS 420 may classify a fault detected based on voltage of a cell being under a pre-defined voltage as a delayed hazard fault because the cell is not hazardous until the cell is recharged (e.g., not yet spontaneously flammable).
The third (lowest) severity level indicates a fault representing a degradation hazard. Degradation hazard faults include those faults that do not present an immediate or delayed safety risk to the operation of battery cells or their operator, but can lead to reduced operational capabilities of such battery cells. For example, FDS 420 may classify a single ADC failure as a degradation hazard fault because a single ADC failure does not pose any safety risks, but reduces operational capability of the corresponding cell(s).
In some example embodiments, FDS 420 may upgrade the severity level of a fault detected at a cell group from one severity level to another severity level when multiple faults are detected at the cell group within a certain time period. For example, FDS 420 may detect a delayed hazard fault or degradation fault based on measurements obtained at the cell group, and upgrade the severity level of that fault to the immediate hazard level if the fault is detected following detection of one or more other faults at the cell group within a predefined time period.
In some embodiments, FDS 420 is operable to classify detected faults by their type. A type of fault may indicate a type of remedial action that should be implemented to address the detected fault.
FDS 420 may classify faults into three types: operational faults, behavioural faults, and system faults. Operational faults arise when a cell operates outside its SOA (as defined by safe operating limits) or outside its NOA (as defined by normal operating limits).
When a battery cell operates outside its SOA, the cell safety is compromised and an immediate or delayed hazard may arise, e.g., cell may catch fire. When a cell operates outside its NOA but within its SOA, no hazard is likely to arise. However, breaching the normal operating limits during cell operation is likely to reduce cell's capacity or cell's lifetime over time, beyond expected degradation.
Both SOA and NOA for a battery cell may be defined by setting respective operating limits based on the cell's manufacturing specification. For example, a SOA for a battery cell can be defined as the voltage, current, and temperature conditions within which the battery cell is expected to operate without being damaged or creating a hazard to the operator.
In some example embodiments, safe operating limits, normal operating limits, or both are defined by conditions for measured properties of a cell, e.g., voltage conditions, temperature condition, current conditions, or any combination thereof. Examples of such conditions include but are not limited to a voltage measured at a cell being over or under a pre-defined voltage, or a temperature of a cell being over or under a pre-defined temperature.
In some example embodiments, safe operating limits, normal operating limits, or both are defined using functions of multiple measured properties, calculated parameters, or combination thereof. For example, safe operating limits may be defined as a variable maximum discharge current for a cell that reduces as the state of charge for the cell approaches zero or as the temperature is lowered.
In some example embodiments, safe operating limits, normal operating limits, or both are defined using various combinations of conditions and functions.
Behavioural faults arise when a cell is not operating as expected. For example, a behavioural fault may be detected when behaviour of a particular cell differs from behaviour of neighbouring cells, e.g., its temperature fluctuates more than that of its neighbours, although all detected fluctuations are within safe operating limits and normal operating limits. A behavioural fault may also be detected when a cell responds to a given stimulus differently from what is expected from the cell as, for example, defined by a corresponding model, even though the measured properties of the cell fall within safe operating limits and normal operating limits.
System faults include faults arising within CMD 400 or with attachments to cells monitored by CMD 400. System faults may, for example, be detected based on reference measurements obtained by self-diagnostic sensors 412, when ADC measurement of an internal fixed reference is incorrect, or when an open circuit is detected on voltage sense lines.
CMD 400 may implement various levels of self-testing and self-diagnostic to identify system faults. These include, but are not limited to, ADC operational checks, analogue multiplexer (MUX) operational checks, error correction circuitry on random-access memory (RAM) and flash memory, stack overflow detection, Cyclic Redundancy Check (CRC) in message packets, open circuit detection, watchdog to reset system in event of lock up or run-away operation, identification of communications failure between sub element of CMD 400, or any combination thereof.
Additional non-limiting examples of faults and related cell models are described with reference to
Returning to
In some embodiments, processor system 422 takes the form of a microcontroller. Additionally or alternatively, processor system 422 may include a microprocessor, a digital signal processor (DSP), an embedded processor, or the like, or may be integrated in a system on a chip (SoC). In some embodiments, processor system 422 includes a processor from the family of processors manufactured by Intel®, AMD®, Qualcomm®, Apple®, NVIDIA®, or the like. Processor system 422 may also be based on the ARM architecture, a mobile processor, etc.
In some embodiments, processor system 422 may be powered down when not in use. Processor system 422 may then be restarted with a signal received from FDS 420, communication system 424, or timer or clock 428.
Communication system 424 enables communication by processor system 422 with BMS 430 or an external device or system. In some embodiments, communication system 424 includes one or more components for enabling communication between CMD 400 and external devices or systems, such as a transceiver, a receiver, a transmitter, or combination thereof. Communication system 424 may support wireless communications, for example, using Bluetooth® or Near Field Communication (NFC) protocols. Alternatively or additionally, communication system 424 may support a wired connection with BMS 430, e.g., USB, CANbus, parallel bus, or another type of wired connection suitable for purpose.
Processor system 422 uses communication system 424 to share the status of the monitored cells, including any detected faults and related fault data, with external systems, such as BMS 430. CMD 400 may share results of fault detection upon FDS 420 completing evaluation of received measurements. In some embodiments, CMD 400 time-shifts, e.g., delays, its communication of a status of the monitored cells, including any detected faults and related fault data, to BMS 430. For example, rather than sharing results, once FDS 420 completes its evaluation of the received measurements, CMD 400 delays communicating the results until a pre-scheduled time or until CMD 400 receives a corresponding request from BMS 430 or an external device or system.
To enable such time-shifting, processor system 422 stores data concerning the status of monitored cells, any faults that FDS 420 detects, and related fault data at fault store 426 for subsequent retrieval along with timing information indicating when, if any, respective faults were detected. Processor system 422 is then able to retrieve relevant data from fault store 426 and share the retrieved data through communication system 424 with a third party, such as BMS 430 that manages a battery system including the cells monitored by CMD 400 and, alternatively or additionally, an external system or device, for example, for subsequent analysis of the SoH history of cells monitored by CMD 400.
Fault store 426 is memory that includes one or more storage devices for storing data concerning faults detected at cells monitored by CMD 400, such as results of evaluation by FDS 420. The one or more storage devices may include, but are not limited to, flash memory (e.g., NOR flash or NAND flash), static random-access memory (SRAM), dynamic random-access memory (DRAM), ferroelectric random-access memory (FRAM), erasable programmable read-on memory (EPROM), electrically erasable programmable read-on memory (EEPROM), non-volatile random-access memory (NVRAM), and/or any other suitable storage device.
Data stored at fault store 426 to capture the state of cells monitored by CMD 400 over time (referenced in this disclosure as cell state data) includes a fault indicator, indicating that a fault has been determined at one or more cells, and data related to the determined fault (referenced in this disclosure as fault data), such as a timestamp of when CMD 400 detected the fault. Cell state data may also include measurements taken at the monitored cells when no fault was detected, derivatives of such measurements, or both, along with information indicating timing of when the measurements were received by FDS 420 or processor system 422 from sensor system 410.
In some embodiments, the fault indicator takes the form of a flag or designated bit (e.g., “0” or “1” designated bit) to indicate that CMD 400 determined a fault.
In some embodiments, the fault indicator is configured to indicate a type of the detected fault (e.g., operational fault, behavioural fault, or a system fault), a severity level of the detected fault (e.g., immediate hazard, delayed hazard, or degradation hazard), the nature of the detected fault (e.g., indicates property(es) that have exceeded their NOA or SOA), or any combination thereof. For example, the fault indicator may include 8 bits, including 2 bits to indicate a severity level of the detected fault or that no fault occurred, 2 bits to indicate a type of the detected fault, and 4 bits to indicate the nature of the detected fault.
In some embodiments, presence of fault data in a message or update from CMD 400 to BMS 430 serves as the fault indicator that CMD 400 detected a fault, while absence of fault data indicates that no fault has been detected.
Fault data includes timing information indicating when FDS 420 detected a fault. For example, the timing information may take the form of a timestamp generated based on output of timer or clock 428 when FDS 420 detected the fault. Fault data may also include measurements (original, derivative, or both) that resulted in FDS 420 detecting the fault, calculations related to detecting the fault, other data related to the fault being detected (e.g., corresponding measurements taken at the cell prior to the fault being detected), or any combination thereof.
When CMD 400 is operable to transmit results of evaluation that FDS 420 performed on the received measurements without time-shifting, such evaluation results include a fault indicator and fault data. These may take the same form as the fault indicator and fault data described as being stored at fault store 426.
Although shown as a separate component in
As explained with reference to
With reference to
Respective cell model 421 defines maximum safe operating voltage limit 506. Sensor system 410 is operable to measure repeatedly voltage of the monitored cells using the voltage sensor. For example, sensor system 410 may measure voltage with a frequency of at least 10 Hz. FDS 420 is operable to compare the obtained measurements to safe operating voltage limit 506 using cell model 421 to determine whether to detect a fault.
Since the voltage at each cell group exceeded maximum safe operating voltage 506, the cells in the cell groups may have been damaged and have the potential to catch fire. Therefore, where FDS 420 or CMD 400 is operable to determine severity levels of detected faults, FDS 420 or CMD 400 may classify the detected fault for both cell groups as having the severity level of an immediate hazard fault. Table 1 provides illustrative examples of maximum safe voltage limits for particular types of lithium-ion cells.
Although the example scenarios of
With reference to
Respective cell model 421 defines safe operating temperature limit 511. Sensor system 410 is operable to obtain temperature measurements at or of the monitored cells using the temperature sensor(s), for example, with a frequency of at least once per second. FDS 420 is operable to compare the obtained measurements to safe operating temperature limit 511 using cell model 421 to determine whether to detect a fault.
Since the temperature of each cell group exceeded maximum safe operating temperature 511, the cells likely to have been damaged and have the potential to catch fire. Therefore, the detected fault for both cell groups may be classified as having the severity level of an immediate hazard fault.
Table 2 provides illustrative examples of maximum safe temperature limits for particular types of lithium-ion cells.
Although the example shown in
With reference to
Respective cell model 421 defines safe operating current limits 514 and 516. Sensor system 410 is operable to obtain measurements of the monitored cells using the current sensor with a frequency of every 10 mS. FDS 420 is operable to compare the obtained measurements with safe operating limits 514 and 516 using cell model 421 to determine whether a cell experienced a fault.
Plot 517 depicts that the current flowing through a respective cell group exceeded maximum safe continuous current limit 5161 for a period of time longer than safe time pulse limit 5141 to 5142. Thus, although the current represented by plot 517 did not exceed maximum safe current pulse limit 5162, plot 517 indicates that a fault arose at the respective cell group.
Plot 518 depicts that the current flowing through a respective cell group experienced a pulse. Although duration of the pulse depicted by plot 518 was within safe time pulse limits 5141 to 5142, the current value of the pulse exceeded maximum safe current pulse limit 5162. Thus, plot 518 also indicates that a fault arose at the respective cell group.
Similar to plot 518, plot 519 depicts that the current flowing through a respective cell group experienced a pulse. However, unlike the spiked pulse of plot 518 and excessively long pulse of plot 517, the pulse of plot 519 did not exceed safe time pulse limit 5141 to 5142, maximum safe continuous current limit 5161. or maximum safe current pulse limit 5162. Thus, plot 519 does not indicate a fault.
Since the current depicted by plots 517 and 518 exceeded at least one safe operating limit, the respective cells likely to have been damaged and have the potential to catch fire without delay. Therefore, the detected faults may be classified as having the severity level of an immediate hazard fault.
Table 3 provides illustrative examples of safe operating current limits for particular types of cells.
Although the example shown in
The pulse time limit approach described with reference to
With reference to
Respective cell model 421 defines minimum safe operating voltage limit 521. Sensor system 410 is operable to obtain voltage measurements of monitored cells using the voltage sensor with a frequency of at least every 100 mS. FDS 420 is operable to compare the obtained measurements to minimum safe operating voltage limit 521 using cell model 421 to determine whether a cell experienced a fault.
Both plots 522 and 523 indicate that a corresponding cell group experienced a fault and would be so interpreted by respective cell model 421. Since the voltage at each cell group fell below minimum safe operating voltage 521, the cells in the cell groups likely to have been damaged, and that damage may cause a delayed hazard. Therefore, CMD 400 may classify the determined fault for both cell groups as having the severity level of a delayed hazard fault where FDS 420 is operable to determine severity levels of determined faults.
Plot 524 depicts a scenario where the cell terminal voltage of the respective cell never falls below minimum safe operating voltage limit 521, and cell model 421 will not detect any fault in relation to plot 524.
Table 4 provides illustrative examples of maximum safe voltage limits for particular types of lithium-ion cells.
Although the example scenarios of
With reference to
Respective cell model 421 defines minimum safe operating temperature limit 526. Sensor system 410 is operable to obtain temperature measurements at or of the monitored cells using the temperature sensor(s), for example, with a frequency of at least once per second. FDS 420 is operable to compare the obtained measurements to minimum safe operating temperature limit 526 using cell model 421 to determine whether to detect a fault.
Cell model 421 may employ different minimum safe operating temperature limits depending on whether a cell group is charging, discharging, or being stored when temperature measurements at or of the cell group are obtained.
Both plots 527 and 528 indicate that a fault occurred at the respective cell group. Since the temperature of each cell group fell below minimum safe operating temperature 526, the cells likely to have been damaged, and that damage may cause a delayed hazard. Therefore, the detected fault for both cell groups may be classified as having the severity level of a delayed hazard fault.
Plot 529 depicts a scenario where the temperature of the respective cell never falls below minimum safe operating temperature limit 526, and cell model 421 will not determine any fault in relation to plot 529.
Table 5 provides illustrative examples of minimum safe temperature limits for particular types of lithium-ion cells.
Although the example shown in
With reference to
Respective cell model 421 defines maximum safe operating pressure limit 531. Sensor system 410 is operable to obtain pressure measurements of monitored cells using a pressure sensor, for example, with a frequency of 1 Hz. Sensor system 410 may measure the internal pressure of a cell directly, for example, using a gas pressure sensor integrated within the cell enclosure, or indirectly, using a sensor that measures the effects of pressure. Examples of sensors that allow measuring the effects of internal cell pressure include, but are not limited to, a force sensor configured to measure the force exerted by the cell onto an external surface caused by a change of internal pressure, and a strain gauge configured to monitor the deflection of the cell enclosure caused by a change of internal pressure.
FDS 420 is operable to compare pressure measurements to maximum safe operating pressure limit 531 using cell model 421 to determine whether to detect a fault. If sensor system 410 measures the internal cell pressure by its effects, then maximum safe operating pressure limit 531 represents a maximum safe operating limit for the measured effect, e.g., maximum safe operating force or maximum safe operating deflection.
Cell pressure is directly proportional to temperature. Therefore, maximum safe operating pressure limit varies as the temperature of a cell raises or lowers. In some embodiments, cell model 421 compensates the obtained pressure measurements or maximum safe operating pressure limit 531, or both, for the temperature conditions present when sensor system 410 obtained respective pressure measurements, before comparing the obtained pressure measurements to maximum safe operating pressure limit 531. For example, cell model 421 may receive both pressure and temperature measurements contemporaneously as input from respective sensors. By compensating pressure measurements or maximum safe operating pressure limit 531 for temperature condition, FDS 420 can assess more accurately whether the obtained pressure measurements indicate a fault, than if no temperature compensation is performed.
Since the internal pressure of each cell exceeded maximum safe operating pressure 531, the cells likely to have been damaged and have the potential to catch fire, vent, or explode. Therefore, the detected fault for both cell groups may be classified as having the severity level of an immediate hazard fault.
As an example, cell model 421 would deem that a cell is experiencing a fault if its internal pressure exceeds 100 kPa at 25 degrees Centigrade. A maximum safe operating pressure limit (over-pressure threshold) may vary for different cells and different cell manufacturers.
Although the example shown in
The internal cell pressure spiking for a short (brief) time period and subsequently returning to a lower pressure can indicate a delayed hazard at a respective cell (such as sudden evolution of gas due to a localised short circuit or dendrite growth), even if the internal pressure during the spike remains within bounds of SOA or NOA. Therefore, in some embodiments, respective cell model analyses internal pressure measurements of a cell for rapid increases and decreases. This scenario is shown in
In some embodiments, when a cell or cell group is behaving not as expected, a CMD, such as CMD 400, is operable to detect a corresponding behavioural fault. Respective cell model 421 defines expected behaviour of the cell or cell group. For example, cell model 421 may define expected values or range of values for measured properties of the cell or cell group responsive to a given stimulus. When behaviour of a monitored cell or cell group deviates from the cell behaviour defined by a respective cell model 421, FDS 420 detects a fault, even if measurements obtained at the monitored cell or cell group fall within safe operating limits and normal operating limits.
One or more thresholds may be used to determine whether behaviour of the monitored cell or cell group deviates from the modelled behaviour. Different thresholds may be used for different cell properties, different cell states, different conditions, etc.
Additionally or alternatively, in some embodiments, CMD 400 is operable to compare measurements obtained at different cells to identify faults. For example, CMD 400 may compare measurements that sensor system 410 obtains at cells within the same cell group monitored by CMD 400, using independent sensors (e.g., gas pressure sensors). Anomalies or deviations in measurements exhibited by one cell in the cell group when compared to measurements obtained at the other cells in the cell group can indicate a behavioural fault, even if the deviating measurements fall within respective safe operating limits or normal operating limits.
Additionally or alternatively, CMD 400 may compare measurements obtained at a monitored cell or cell group with corresponding measurements obtained at neighbouring cells that are not monitored by CMD 400. Anomalies or deviations in measurements exhibited by a monitored cell or the cell group when compared to measurements obtained at the neighbouring cells can indicate a behavioural fault at the monitored cell or cell group, even if the measurements obtained at the monitored cell or cell group fall within respective safe operating limits or normal operating limits. CMD 400 may be operable to receive measurements of neighbouring cells directly from CMD(s) monitoring the neighbouring cells or through BMS 430.
Variations between the rate of change of temperature measured at a monitored cell or cell group and a rate of change of temperature predicted by a thermo-electrical model of the cell or cell group for a known stimulus (e.g., voltage, current, or both) and the state of the cell or cell group (e.g., a state of charge, a SoH, or internal resistance) can be indicative of a behavioural fault at the monitored cell or cell group. In some embodiments, cell model 421 defines a thermo-electrical model of expected temperature changes for the monitored cell or cell group responsive to predefined stimuli in preset cell states, and a deviation threshold. When the rate of change of temperature of the monitored cell or cell group deviates from a rate of change predicted by the thermo-electrical model by more than the predefined deviation threshold, FDS 420 of CMD 400 is operable to detect a fault. For example, if cell model 421 predicts that a 1A current should lead to rise of temperature from 25 to 30 degrees after 1 minute, while corresponding measurements obtained at the monitored cell or cell group reflect the same rise in 30 seconds, then FDS 420 of CMD 400 would detect a behavioural fault.
Variations in behaviour between the same type of cells being exposed to the same stimulus can indicate that a fault arose at one or more such cells. For example, a rate of change of temperature measured at one cell or cell group being different from a rate of change of temperature measured at other cells or cell groups for the same stimulus (e.g., voltage and current) and considering the state of the respective cells or cell groups (e.g., a state of charge, a SoH, or internal resistance) can indicate a behavioural fault at the cell or cell group whose rate of change deviates from the others.
In some embodiments, cell model 421 defines one or more deviation thresholds for use when comparing measurements of different cells or cell groups. For example, different deviation thresholds may be set for different stimuli, cell states, or both.
When FDS 420 determines that a rate of change of temperature of a monitored cell or cell group deviates from a rate of change of neighbouring cells or cell group by more than a corresponding deviation threshold of model 421, FDS 420 detects a behavioural fault. For example, if FDS 420 determines that all cells in a battery system remain at a constant 30 C. except for a cell or cell group that CMD 400 monitors and that cell or cell group's temperature rises to 40 C, FDS 420 determines a behavioural fault.
Variations between the rate of change of voltage measured at a monitored cell or cell group and a rate of change of voltage predicted by a thermo-electrical model of the cell or cell group for a known stimulus (e.g., temperature, current, or both) and the state of the cell or cell group (e.g., a state of charge, a SoH, or internal resistance) can be indicative of a behavioural fault arisen at the cell or cell group. In some embodiments, cell model 421 defines a thermo-electrical model of expected voltage changes for the monitored cell or cell group responsive to predefined stimuli in preset states, and a deviation threshold. When the rate of change of voltage of the monitored cell or cell group deviates from a rate of change predicted by thermo-electrical model by more than the predefined deviation threshold, FDS 420 of CMD 400 is operable to detect a fault. For example, if cell model 421 predicts that with zero current and stable temperature, the voltage should drop by no more 50 mV in an hour, while corresponding measurements obtained at the monitored cell or cell group reflect the same drop in 10 minutes, then FDS 420 of CMD 400 would detect a behavioural fault.
Variations in behaviour between the same type of cells being exposed to the same stimulus can indicate that a fault arose at one or more such cells. For example, a rate of change of voltage measured at one cell or cell group being different from a rate of change of voltage measured at other cells or cell groups for the same stimulus (e.g., current, temperature, or both) and considering the state of the respective cells or cell groups (e.g., a state of charge, a SoH, or internal resistance) can indicate a behavioural fault at the cell or cell group whose rate of change deviates from the others.
In some embodiments, cell model 421 defines one or more deviation thresholds for use when comparing measurements of different cells or cell groups. Different deviation thresholds may be set for different stimuli, cell states, or both. A difference between measurements of compared cells exceeding a respective deviation threshold indicates a behavioural fault.
When FDS 420 determines that a rate of change of voltage of a monitored cell or cell group deviates from a rate of change of neighbouring cells or cell group by more than a corresponding deviation threshold of model 421, FDS 420 detects a behavioural fault. For example, if FDS 420 determines that all cells in a battery system remain at a constant 3.7 V+50 mV, except for a cell or cell group that CMD 400 monitors, and that cell or cell group's voltage drops to 3.5 V, FDS 420 determines a behavioural fault.
In some embodiments, divergence in cell voltages between different cells is evaluated in relation to a time period over which the divergence has occurred. A gradual divergence in cell voltages between different cells is expected over long (extended) periods of time (such as days to months), and thus is not necessarily indicative of a fault. Thus, the same level of divergence may indicate a behavioural fault when detected over minutes or hours, but not indicate a behavioural fault when detected over days or months. The deviation threshold therefore may be adjusted depending on the time period over which the divergence is detected. For example, the deviation threshold may increase as the time period over which the divergence between the cells is detected increases.
Variations between the rate of change of internal pressure of a monitored cell and a rate of change of internal pressure predicted by a model of the cell for a known stimulus (e.g., voltage, temperature, current, or a combination thereof) and the state of the cell or cell group (e.g., a state of charge, a SoH, or internal resistance) can be indicative of a behavioural fault at the cell. In some embodiments, cell model 421 defines modelled internal pressure changes for the monitored cell responsive to predefined stimuli in preset states, and a deviation threshold. When the rate of change of internal pressure of the monitored cell deviates from a rate of change predicted by respective model 421 by more than the predefined deviation threshold, FDS 420 detects a fault.
In some embodiments, cell model 421 defines one or more thresholds for predefined stimuli and preset state. When FDS 420 determines that the rate of change of internal pressure of the monitored cell exceeds a corresponding threshold, FDS 420 detects a fault. For example, cell model 421 may set a maximum rate of change of pressure threshold of +/−0.1 kPa/s. If FDS 420 determines, based on respective measurements at the monitored cell, that the rate of change of pressure is greater than the preset threshold, FDS 420 detects a behavioural fault.
The internal pressure of a cell is expected to increase over the cell life, where the pressure is proportional to that cell's SoH. In some embodiments, cell model 421 sets out the relationship between cell pressure and SoH. If FDS 420 determines, based on respective measurements at the monitored cell, that cell pressure increased more than expected, FDS 420 detects a behavioural fault. If FDS 420 determines, based respective measurements at the monitored cell, that cell pressure decreases when the pressure is expected to increase over time a cell, FDS 420 detects a behavioural fault. Such a decrease is indicative of the cell having a leak.
Variations in behaviour between the same type of cells being exposed to the same stimulus can indicate a fault at one or more such cells. For example, an internal pressure of one cell in a battery pack being different from an internal pressure of other cells in the same pack for the same stimulus (e.g., voltage, temperature, current, or combination thereof) and considering the state of the respective cells (e.g., a state of charge, a SoH, or internal resistance) can indicate a behavioural fault at the cell whose internal pressure deviates from the others.
In some embodiments, cell model 421 defines one or more deviation thresholds for use when comparing measurements of different cells or cell groups. For example, different deviation thresholds may be set for different stimuli, cell states, or both.
When FDS 420 determines that an internal pressure of a monitored cell deviates from an internal pressure of neighbouring cells by more than a corresponding deviation threshold of model 421, FDS 420 detects a behavioural fault. For example, if FDS 420 determines that all cells in a battery system or pack are at cell pressure of 50 kPa, except for a cell that CMD 400 monitors, and that cell's pressure is above or below of that of the other cells by a given percentage, or more than a given percentage (e.g., a deviation threshold of 5%), FDS 420 determines a behavioural fault.
In some embodiments, the frequencies with which sensor system 410 measures various cell properties discussed with reference to
In some embodiments, one more cell models 421, such as cell models described with reference to
Multiple example scenarios have been described with reference to
In addition to the functions described with reference to
ADC 619 provides extra measurements to FDS 620, which FDS 620 evaluates for functional safety related fault(s). ADC 618 and ADC 619 use different conversion techniques. In some embodiments, ADC 618 achieves a higher precision with a faster conversion rate than ADC 619 and is able to support cell voltage or other measurements of many times a second, e.g., 100 Hz instead of 10 Hz or slower supported by ADC 619. For example, ADC 618 may have a sigma-delta architecture with minimum of 16-bit resolution, while ADC 619 may have a successive-approximation architecture with a lower resolution than ADC 618, e.g., 12-14 bit. In this manner, ADC 619 enables FDS 620 to perform functional safety checks on ADC 618. This improves safety and reliability of CMD 600 when compared to that of CMD 400.
Additional one or more ADCs may be added to CMD 600, with the additional one or more ADCs contributing to the redundancy within CMD 600. For example, the use of additional ADC(s) could offer further enhancements of the reliability and safety by using techniques such as 2 out of 3 voting or enhanced safety in the event of single ADC failure.
Unlike CMD 400, whose processor system 422 controls data communication by FDS 420, in CMD 600, FDS 620 is able to share its data directly with communication system 624. Direct communication between FDS 620 and communication system 624 enables communication system 624 to include cell status information, such as faut indicator and fault data received from FDS 620, in addition to and independent from corresponding cell status information received from processor system 622. In this manner, CMD 600 provides for a diverse and redundant fault determination. When corresponding cell status information provided by processor system 622 and FDS 420 matches, BMS 430 is assured that the cell status information is accurate. Discrepancies between corresponding cell status information provided by processor system 422 and FDS 420 would indicate to BMS 430 that CMD 600 is experiencing a fault and remedial action may be needed.
In CMD 600, FDS 620 also has direct access to fault store 626, and thus is able to store cell status information directly in fault store 626. In some embodiments, this reduces processing load on processor system 622 by making FDS 620 solely responsible for storing its data at fault store. In some other embodiments, processor system 622 runs an additional self-diagnostic check by comparing cell status information processor system 622 receives from FDS 620 with corresponding cell status information that FDS 620 stores at fault store 626.
Although, as described, CMD 600 differs from CMD 400 in that it employs additional ADC(s), allows for direct communication between FDS 620 and communication system 624, and gives FDS 620 direct access to fault store 626, such differences may be introduced into CMD 400 individually or in any combination to enhance reliability and safety of CMD 400.
System 700 includes a plurality CMDs 7201 . . . 720N, such as CMD 400 or CMD 600, for respectively monitoring the cell status of cell groups (CG) 7121 . . . 712N. System 700 also includes BMS 730 for monitoring and managing performance of battery system 710. System 700 includes one CMD 720 per each cell group 712. Each CMDs 720; is attached to, incorporated with, or otherwise associated with respective cell group 712; as to be able to monitor cells in cell group 712i.
To monitor and manage the performance of battery system 710, BMS 730 is operable to communicate with each of CMDs 7201 . . . 720N to gather and process cell status information provided by CMDs 720, including fault indicators and related fault data. BMS 720 is also operable to control environment of battery system 710 and balance battery system 710.
BMS 730 includes CMD communication system 731 operable to enable communication between BMS 730 and CMDs 720, processor system 735 configured to effect operations of BMS 730 and its components, fault evaluation system 737 operable to process cell status information received from CMDs 720, including fault indicators and related fault data, and external communication system 739 operable to enable BMS 730 to communicate with various external systems and devices 740.
BMS 730 also includes sensors 733 operable to measure properties of battery system 710. In some embodiments, sensors 733 measure properties that are not necessarily measured by individual CMDs 720, such as but not limited to, a temperature sensor for measuring temperature at battery system 710 or at a battery pack included in battery system 710, a voltage sensor for measuring voltage of battery system 710 or at a battery pack included in battery system 710, a current sensor for measuring current flowing in and out of battery system 710 or at a battery pack included in battery system 710, where a battery pack includes multiple cell groups. Additionally or alternatively, sensors 733 may measure properties of individual cells and cell groups to introduce additional redundancy into system 700 to improve its overall reliability and safety.
In some embodiments, fault evaluation system 737 is operable to gather cell status information from CMDs 720 and, if such cell status information includes fault indicators, inform external system 740 that one or more faults have arisen at battery system 710 and share relevant fault data with external system 740.
External system or device 740 is operable to receive cell status information from BMS 730, including results of processing performed by BMS 730, and process the received data to identify possible remedial actions. External system 740 may be in general proximity to BMS 730, e.g., a vehicle engine control unit or another system in an electric vehicle, or be remote, e.g., an IOT server.
In some embodiments, fault evaluation system 737 analyses received cell status information to confirm faults detected by CMD 720. For example, if CMD 720 shares redundant information regarding identified faults, as for example described with reference to
Additionally or alternatively, fault evaluation system 737 is operable to compare cell status information received from multiple CMDs to perform one or more of: confirm faults, classify faults, identify fault source(s), or evaluate behaviour of different cell groups to identify faults. Fault evaluation system 737 may use the same techniques as described with reference to
System 800 also includes IOT cloud service 850 for processing faults based on information provided by BMS 7301 to BMS 730M. IOT cloud services 850 includes database 852 for storing fault data as well as information relevant to identification of faults, database controller 858 for controlling database 852, such as data retrieval by external systems 840, fault evaluation system 856 for evaluating fault data and analysing faults, including to identify remedial actions, and IOT communication system 854 for enabling data exchange between systems 7001 to 700M and IOT cloud services 850 and external systems 840 and IOT cloud services 850. IOT cloud service 850 maintains knowledge of the expected behaviour of many applications, and with that understanding is able to suggest remedial action to extend application longevity such as a change in the NOA specification. IOT cloud service 850 may employ Artificial Intelligence (AI) techniques, machine-learning techniques, or both to continuously evolve the knowledge database.
In some embodiments, system 800 monitors the status of a single battery system where each system 700; is responsible for monitoring the status of a respective battery pack in the battery system. This arrangement allows for parallel processing of property measurements and fault detection by CMDs 720 and BMS 730i, thereby providing relevant fault information to and alerting fault evaluation system 856 faster than a single system 700 could. This arrangement also enables fault evaluation system 856 to analyse and compare fault data at three different levels: based on property measurements obtained at the cell group level, based on evaluation results drawn at the CMD level (e.g., at the level of CMD 400 or 600), and based on evaluation results drawn at the BMS level (e.g., at the level of BMS 730). System 800 may apply the BMS level analysis, when information received from different systems 700 is consistent, and move to verifying the CMD level analysis or the cell group level analysis when information shared by different systems 700 differs. System 800 has knowledge of the performance of all the cells, CMDs and BMSs, and thus is able detect faults that cannot be identified by a single BMS in isolation. This allows for more efficient evaluation by fault evaluation system 856 while ensuring safety and accuracy when needed.
In some embodiments, system 800 monitors the status of multiple battery systems where each system 700; is responsible for monitoring the status of a respective battery system. Different battery systems may be located at different locations and/or perform different tasks. This arrangement allows fault evaluation system 856 to apply and share knowledge based on fault analysis performed at different battery systems. For example, if system 800 monitors the status of multiple battery systems of the same type, fault detection across all such battery systems can be improved based on experience at one or more of such battery systems. System 800 may employ machine learning or AI techniques to improve fault detection. This approach also facilitates identification of scenarios where a recall of a particular type of battery system is appropriate and implementation of the recall.
With reference to
External stimulus activates ON mode 910 at BMS 1030. For example, if a battery system monitored by BMS 1030 is used in an electric vehicle, turning the key switch or ignition on provides external stimulus that activates ON mode 910 at BMS 1030. Another external stimulus or removal of the original stimulus causes BMS 1030 to transition from ON mode 910 to Safe Sleep mode 920. In the electric vehicle example, turning the key switch or ignition off removes the original stimulus, thereby causing BMS 1030 to transition to Safe Sleep mode 920.
While in Safe Sleep mode 920, BMS 1030 is not operated and consumes only minimal power. Repeatedly, BMS 1030 wakes up and transitions from Safe Sleep mode 920 to Safe Sleep (polled) mode 930 to assess the state of the monitored battery system based on data provided by CMDs 1020. Upon completing assessment of the monitored battery system and performing related actions (e.g., reporting to an external system), BMS 1030 transitions back to Safe Sleep mode 920. BMS 1030 may wake from Safe Sleep mode 920 periodically, at regular timed intervals, e.g., every 15 minutes, random time intervals, or time intervals determined based on the state of monitored battery system. In the latter scenario, the time interval may, for example, decrease as obtained cell measurements approach the bounds of a respective SOA or NOA and increase as obtained cell measurements move further away from the SOA or NOA bounds or when cell measurements are well within the SOA or NOA bounds (e.g., as defined by respective threshold(s)).
In some embodiments, an external stimulus is used to activate first Safe Sleep mode 920 or Safe Sleep (polled) mode 930, rather than activating ON mode 910, at BMS 1030.
As shown in
In some embodiments, CMD 1020 communicates with BMS 1030 about a fault immediately upon determining such a fault. In these embodiments, CMD 1020 performs informing step 1029 prior to storing step 1025, with no time shifting.
At step 1031, BMS 1030 processes the measurements received from each CMD 1020 for faults independent of the analysis performed by respective CMD 1020. Additionally or alternatively, BMS 1030 analyses measurements receives from CMDs 1020 collectively using measurements obtained by multiple CMDs, for example, by comparing measurements received from one CMD 1020 against measurements received from other CMDs 1020, to determine whether a fault detected by CMD 1020 has occurred.
BMS 1030 communicates determined faults and related data to external systems 1040 and/or IOT cloud 1050 (steps 1033 and 1035 respectively). In some embodiments, BMS 1030 communicates with external systems 1040 and/or IOT cloud 1050 concerning a detected fault with no time shifting. i.e., immediately upon determining that a fault has occurred. In some other embodiments, BMS 1030 time shifts the sharing of data concerning determined faults with external systems 1040, IOT cloud 1050, or both, i.e., there is a delay between BMS 1030 determining a fault at the battery system and communicating information regarding such a fault to external systems 1040, IOT cloud 1050, or both. For example, BMS 1030 may share information about a determined fault with external systems 1040, IOT cloud 1050, or both only after BMS 1030 stores such information locally at BMS 1030. BMS 1030 may also wait to receive a request for a status update on the battery system from external systems 1040, IOT cloud 1050, or both before sharing information about faults detected at the battery system.
BMS 1030 also communicates with external systems 1040, IOT cloud 1050, or both concerning faults determined by CMDs 1020 (steps 1037 and 1039 respectively). In some embodiments, BMS 1030 communicates with external systems 1040 and/or IOT cloud 1050 concerning a fault detected by CMD 1020 immediately upon CMD 1020 transmitting a fault indicator and related fault data to BMS 1030, with no time shifting.
In some other embodiments, BMS 1030 time shifts communications with external systems 1040 and/or IOT cloud 1050 concerning faults detected by CMDs 1020 by having a time delay between receiving respective data from CMDs 1020 and transmitting such data to external systems 1040 and/or IOT cloud 1050. For example, BMS 1030 may store data received from CMDs 120 before passing it on to external systems 1040 and/or IOT cloud 1050. Additionally or alternatively, BMS 1030 may also compare such data to its own analysis of corresponding measurements received from CMDs 1020 to verify faults detected by CMDs 1020 before informing external systems 1040 and/or IOT cloud 1050 about faults detected at the monitored battery system.
Upon receiving data concerning a fault detected at monitored battery systems, external systems 1040 and IOT cloud 1050 identify and effect a corresponding remedial action (steps 1041 and 1051 respectively). Returning to the electric vehicle example, an external system in the form of a vehicle management unit may cause an alert to be displayed on the dashboard of the vehicle or an audible warning to be issued instructing the driver to steer to a safe place, and whereupon instruct the BMS to disconnect the battery from the power source, such as the powertrain. An IOT cloud may determine a degradation hazard fault through analysis of data from multiple battery systems. For example, a fault due to the NOA being set too wide for a particular type of battery cells can be determined by analysing multiple systems with different use profiles. The IOT Cloud can then instruct the external system in the form of the vehicle management unit to modify the vehicle performance NOA, the BMS to change its NOA, and the cell CMDs to change their NOA.
CMDs 1020, BMS 1030, external systems 1040, and IOT cloud 1050 may use different data to determine or confirm faults at monitored cells. For example, BMS 1030 may use data received from multiple CMDs to confirm or determine faults at cells monitored by one of the CMDs, while external system 1040 or IOT cloud 1050 may use data received from multiple BMSs monitoring different batteries. In some circumstances, while CMD 1020 may detect a fault at one or more monitored cells, BMS 1030, external system 1040, or IOT cloud may reach a different conclusion based on data gathered in relation to other cells, such as neighbouring cells. Conversely, while CMD 1020 may detect no fault at one or more monitored cells, BMS 1030, external system 1040, or IOT cloud 1050 may reach a different conclusion based on data gathered in relation to other cells, such as neighbouring cells. For example, BMS 1030, external system 1040, or IOT cloud 1050 may detect a fault at certain cells upon learning that a particular behaviour exhibited by the monitored cells as evidenced by measurements obtained at the monitored cells by the corresponding CMD has led to a fault in similar cells before, notwithstanding that cell measurements were within a corresponding SOA or NOA. In some embodiments, BMS 1030, external system 1040, or IOT cloud 1050 transmits respective data back to CMD 1020 to update locally stored history of faults detected at the respective monitored cells.
Safe Sleep mode 920 is a power saving state of BMS 1030. While in Safe Sleep mode, BMS 1030 is not operated and consumes only minimal power. Therefore, BMS 1030 does not communicate with CMDs 1020, external systems 1040, or IOT cloud 1050.
While BMS 1030 is in Safe Sleep mode 920, each CMD 1020 is in a sleep monitoring mode (also referenced as a monitoring mode). In this mode, CMD 1020 continues to repeatedly measure cell properties (e.g., temperature and voltage) of monitored cells (step 1121) and evaluate the measured cell properties to determine faults, if any, at the monitored cells (step 1123). However, CMD 1020 performs such actions generally less frequently while in the sleep monitoring mode than while in the operational mode. CMD 1020 may measure different properties of monitored cells with different frequencies while in operational mode and reduce such frequencies to different levels while in the sleep monitoring mode. This allows CMD 1020 to continue gathering measurements sufficient to determine faults if any arise at monitored cells, while reducing power consumption by CMD 1020.
For example, CMD 1020 may measure voltage of a monitored group of cells every 10 milliseconds (i.e., with a frequency of 100 Hz) while in the operational mode, and every 500 milliseconds (i.e., with a frequency of 2 Hz) while in the sleep monitoring mode. As another example, CMD 1020 may measure temperature of a monitored cell group or individual cells every 1 second (i.e., with a frequency of 1 Hz) while in the operational mode, and continue to measure temperature of the monitored cell group or individual cells every 1 second (i.e., with a frequency of 1 Hz) while in sleep monitoring mode.
Similar to CMD 400 and 600, the frequency with which CMD 1020 measures various properties of monitored cells may be configurable. For the example, the frequency can be adjusted responsive to measurements obtained at the monitored cells (e.g., voltage, current, temperature, pressure, etc.), a detected state of the monitored cells, measurement trends exhibited by the monitored cells, intended use of the monitored cells, a state of health of the monitored cells, etc.
Similar to the operational mode, if CMD 1020 determines no fault at any of the monitored cells, CMD 1020 returns to measuring step 1121. If CMD 1020 determines a fault at one or more monitored cells, CMD 1020 stores data concerning the detected fault locally at CMD 1020 for later transmission to BMS 1030. Such data comprises a fault indicator and related fault data, including a timestamp indicating when the fault was detected by CMD 1020. Fault data may also include measurements (direct, derivative, or both) based on which CMD 1020 detected the fault. After storing data concerning the detected fault, CMD 1020 returns to measuring step 1121.
Multiple faults may arise at monitored cells, near simultaneously or over time, while BMS 1030 is in Safe Sleep Mode 920. Information concerning all such multiple faults is saved by respective CMDs 1020 in local storage, such as Fault Store 426 or 626, for later communication to BMS 1030.
Repeatedly (e.g., periodically), BMS 1030 wakes and transitions from Safe Sleep mode 920 to Safe Sleep (polled) mode 930 to assess the state of the monitored battery system (step 1131). In some embodiments, Safe Sleep (polled) mode 930 is initiated at BMS 1030, instead of ON mode 910, when BMS 1030 is powered up.
Once in Safe Sleep (polled) mode 930, BMS 1030 informs CMDs 1020 accordingly, for example, by sending a respective wake-up signal to CMDs 1020 (step 1133) to cause CMDs 1020 to transition from the safe monitoring mode to the operational mode. CMDs 1020 may inform BMS 1030 that they have transitioned into the operational mode by sending a corresponding signal (step 1126).
At step 1135, BMS 1030 requests each CMD 1020 to share data regarding faults detected by CMD 1020, measurements obtained by CMDs 1020, or both. BMS 1030 may request CMDs 1020 to share data related to faults detected by CMDs 1020 during the most recent Safe Sleep mode interval, during a certain number of preceding Safe Sleep mode intervals, or a particular time period. BMS 1030 may also request CMDs 1020 to share data related to all faults detected by CMDs 1020, i.e., the entire history of faults detected by CMDs 1020. For the same time periods, BMS 1030 may request CMDs 1020 to share measurements obtained by CMDs 1020 at corresponding cells, any derived measurements, or both.
In response, each CMD 1020 retrieves respective data from a corresponding local fault store (step 1127) and transmits such data to BMS 1030 (step 1129). CMD 1020 may process the retrieved data prior to transmitting such data to BMS 1030, for example to compress or encrypt the data before transmission. CMD 1020 stores timing information (e.g., in the form of timestamps) in association with the measurements and faults, where the timing information indicates when the measurements were obtained, and faults were detected. Therefore, CMD 1020 is able to retrieve data corresponding to any desired time interval using the timing information indicated by timestamps.
Once CMDs 1020 transmit the requested data to BMS 1030, CMDs 1020 continues to operate in the operational mode as described with reference to
At steps 1137 and 1139 BMS 1030 communicates data received from CMDs 1020 concerning detected faults to external systems 1040 and/or IOT cloud 1050, respectively. In some embodiments, BMS 1030 does so immediately upon receiving respective data, with no time shifting. In some other embodiments, BMS 1030 time shifts communications with external systems 1040 and/or IOT cloud 1050 concerning faults detected by CMDs 1020. For example, BMS 1030 may store data received from CMDs 1020 for later retrieval and passing such data on to external systems 1040 and/or IOT cloud 1050.
Additionally or alternatively, BMS 1030 may analyse the measurements received from each CMD 1020 for faults independent of analysis by respective CMD 1020 and compare results of such analysis to information provided by CMDs 1020 to verify faults and faults conditions detected by CMDs 1020 before communicating with external systems 1040 and/or IOT cloud 1050 about faults detected at the monitored cells. BMS 1030 may also analyze measurements receives from CMDs 1020 collectively, using measurements obtained by multiple CMSs, for example by comparing measurements received from one CMD 1020 against measurements received from other CMDs 1020.
Upon receiving data concerning faults detected at the monitored battery cells, external systems 1040 and IOT cloud 1050 identify and effect corresponding remedial actions (steps 1141 and 1151 respectively).
In known systems, an operator starting a vehicle with a battery system monitored by a BMS, powers up a BMS, which causes the BMS to perform a number of checks on monitored battery system (e.g., to confirm that cell measurements are within a respective SOA) before closing a battery system relay to connect the monitored battery system to a power source, such as a charger, or a load such as a powertrain. However, in such systems, the BMS is only aware of the measurements taken when the checks are being performed, and thus may not be aware that a particular cell or cells experienced a fault. For example, although a particular cell may have all its measurements within the SOA at the time of the check, it could have had measurements that fell outside the SOA at some point in time before the vehicle or the other system being started (e.g., a temperature or voltage spike or dip), which indicates that the cell experienced a fault. However, if the BMS is not aware of such measurements, the BMS will proceed with closing the battery system relay, thereby facilitating development of the respective fault.
In accordance with the present disclosure, as for example described with reference to
With reference to
External stimulus activates ON mode 1210 at BMS 1030. For example, if BMS 1330 monitors a battery system in an electric vehicle, turning the key switch or ignition on provides external stimulus that activates ON mode 1210 at BMS 1330. Another external stimulus or removal of the original stimulus transitions BMS 1330 from ON mode 1210 to Safe Sleep mode 1220. In the electric vehicle example, turning the key switch or ignition off removes the original stimulus, thereby causing BMS 1330 to transition to Safe Sleep mode 1220. While in Safe Sleep mode 1220, BMS 1330 is not operated and consumes only minimal power.
Repeatedly (e.g., periodically) BMS 1330 wakes up and transitions from Safe Sleep mode 1220 to Safe Sleep (polled) mode 1230 to assess the state of the monitored battery system or battery pack based on data provided by CMDs 1320. In some embodiments, Safe Sleep (polled) mode 1230 is initiated at BMS 1330, instead of ON mode 1210, when BMS 1330 is powered up.
Upon completing assessment of the monitored battery system and performing related actions, BMS 1330 transitions to Safe Sleep mode 1220. BMS 1330 may wake up from Safe Sleep mode 1220 at regular timed intervals, e.g., every N minutes (e.g., 15 minutes) or every M hours (e.g., 3-4 hours), random timed intervals, or timed intervals determined based on the state of monitored battery system. For example, the time interval may decrease as obtained cell measurements approach the bounds of a respective SOA or NOA and increase, up to a predefined time limit, as obtained cell measurements move further away from the SOA or NOA bounds or when are well within the SOA or NOA bounds.
BMS 1330 transitions to Safe Sleep (alert) mode 1240 from Safe Sleep mode 1210 when BMS 1330 receives an alert signal from CMD 1320 indicating that CMD 1320 detected a fault at one or more monitored cells. In some embodiments, CMD 1320 transmits such an alert to BMS 1330 only when it detects a fault of a predetermined type, for example, a fault having the immediate hazard severity level.
Once in Safe Sleep (alert) mode 1240, BMS 1330 assesses the state of the monitored battery system based on data provided by CMDs 1320 and performs related actions, such as communicating with external systems 1340 and/or IOT cloud 1350 regarding the detected faults. BMS 1330 may then return to Safe Sleep mode 1020.
While BMS 1330 is in ON Mode 1210, CMDs 1320, BMS 1330, external systems 1340, and IOT cloud 1350 operate in the same manner as CMDs 1020, BMS 1030, external systems 1040, and IOT cloud 1050 respectively, while BMS 1030 is ON Mode 910. Detailed description provided with reference to
While BMS 1330 is in Safe Sleep (polled) mode 1230, CMDs 1320, BMS 1330, external systems 1340, and IOT cloud 1350 operate generally in the same manner as CMDs 1020, BMS 1030, external systems 1040, and IOT cloud 1050 respectively, while BMS 1030 is in Safe Sleep (polled) mode 930. Detailed description provided with reference to
While BMS 1330 is in Safe Sleep mode 1220, CMDs 1320, BMS 1330, external systems 1340, and IOT cloud 1350 generally operate in the same manner as CMDs 1020, BMS 1030, external systems 1040, and IOT cloud 1050 respectively, while BMS 1030 is in Safe Sleep mode 920. Detailed description provided with reference to
While BMS 1330 is in Safe Sleeping mode 920, CMD 1320 is in a sleep monitoring mode as CMD 1020 described with reference to
As Safe Sleep mode 920, Safe Sleep mode 1220 is a power saving state of BMS 1330. While in Safe Sleep mode 1220, BMS 1330 is not operated and consumes only minimal power. Therefore, BMS 1330 does not communicate with CMDs 1320, external systems 1340, or IOT cloud 1350. Unlike BMS 1030 of
Similar to CMDs 1020, each CMD 1320 is in a sleep monitoring mode while BMS 1330 is in Safe Sleep mode 1220. In this mode, CMD 1320 continues to repeatedly measure cell properties (e.g., temperature and voltage) of monitored cells (step 1321) and evaluate the measured cell properties to determine faults, if any, at the monitored cells (step 1323). If CMD 1320 determines no fault at any of the monitored cells, CMD 1320 returns to measuring step 1321. If CMD 1320 determines a fault at one or more monitored cells, CMD 1320 stores data concerning the detected fault locally at CMD 1320 (step 1325).
Unlike CMDs 1020, CMD 1320 issues and transmits an alert signal to BMS 1330 to indicate that CMD 1320 determined a fault at one or more monitored cells (steps 1324, 1424). The difference between step 1324 shown in
In some embodiments, CMD 1320 issues an alert signal only if the severity level of a determined fault is an immediate hazard, while with faults of other severity levels, CMD 1320 operates as CMD 1020.
BMS 1330 is operable to receive alert signals from CMDs 1320 and transition from Safe Sleep mode 1220 to Safe Sleep (alert) mode 1240 upon receiving such a signal. In some embodiments, BMS transitions from Safe Sleep mode 1220 to Safe Sleep (alert) mode 1240 only if a received alert signal indicates that the severity level of a detected fault is an immediate hazard. In these embodiments, when a received alert signal does not relate to an immediate hazard fault, BMS 1330 delays further communications with CMDs 1320 until BMS 1330 transitions to Safe Sleep (polled) mode.
With reference to
As BMS transitions to Safe Sleep (alert) mode, CMD 1320 transitions from the sleep monitoring mode to the operational mode. CMD 1320 may transition into the operational mode independently, when sending the alert signal to BMS 1330 or upon receiving a respective command from BMS 1330, or a request for data (fault data, measurements that did not result in detecting of a fault, or both) from BMS 1330. In some embodiments, BMS 1330 sends a wake-up signal to CMD 1320 upon transitioning to Safe Sleep (alert) mode 1240 to cause CMD 1320 to transition into the operational mode.
In response to the received request for data from BMS 1330, CMD 1320 retrieves respective data from a corresponding local fault store (step 1327) and transmits such data to BMS 1330 (step 1329). As CMD 1320 stores timing information, such as timestamps, indicating when measurements were obtained and faults were detected, CMD 1320 can retrieve fault data and measurements corresponding to any desired time interval using the timing information.
CMD 1320 may process the retrieved data prior to transmitting such data to BMS 1330, for example, to compress or encrypt the data before transmission.
Once CMD 1320 transmits the requested data to BMS 1330, CMD 1320 continues to operate in the operational mode as, for example, described with reference to
At steps 1337 and 1339, BMS 1030 communicates data received from CMD 1320 concerning the detected faults and/or measurements taken at the cells monitored by CMD 1320 to external systems 1340 and/or IOT cloud 1350, respectively. In some embodiments, BMS 1330 does so immediately upon receiving respective data, with no time shifting.
In some other embodiments, BMS 1330 time shifts communications with external systems 1340 and/or IOT cloud 1350 concerning the fault detected by CMD 1320. For example, BMS 1330 first may store data received from CMD 1320 for later retrieval and passing on of such data to external systems 1340 and/or IOT cloud 1350. In some embodiments, BMS 1330 transmits data concerning faults detected at the monitored battery system to external systems 1340 and/or IOT cloud 1350 upon receiving a respective request from external systems 1340 and/or IOT cloud 1350.
In some embodiments, upon receiving an alert signal from one CMD 1320 and transitioning into Safe Sleep (alert) mode 1240, BMS 1330 transmits a wake-up signal to remaining CMDs 1320 to transition them into the operational mode. This causes remaining CMDs 1320 to share their data concerning any faults detected at the corresponding cells. BMS 1330 may then analyze measurements received from CMDs 1320 collectively, for example by comparing measurements received from CMD 1320 that issued the alert signal against relevant measurements received from remaining CMDs 1320 to verify the fault detected by CMD 1320 that issued the alert signal. Additionally or alternatively, BMS 1330 may analyze the measurements received from each CMD 1320 for faults independent of analysis by respective CMD 1320 and compare results of such analysis to information provided by CMDs 1320 concerning detected faults to verify faults and faults conditions detected by CMDs 1320.
Upon receiving data concerning faults detected at the monitored battery cells, external systems 1340 and IOT cloud 1350 identify and effect corresponding remedial actions (steps 1341 and 1351 respectively). As external systems 1340 and IOT cloud 1350 receive data from multiple BMSs, and thus have a greater number of data points, they are able to identify systematic causes of faults and differentiate them from random faults more accurately than respective BMSs. BMS 1330 usually would only have knowledge of the behaviour of a battery pack BMS 1330 monitors. A behavioural fault may affect all cells in that pack and could be triggered by a systematic problem in all cells in a respective manufactured batch. Because all cells in the battery pack behave in the same way, BMS 1330 does not have data that would enable BMS 1330 to identify the cell behaviour as incorrect. However external systems 1340 and IOT cloud 1350 are able to compare the behaviour with other similar packs, and thus identify any errant behaviour.
For example, an entire batch of cells, due to a manufacturing defect, have an internal resistance that increases over time. Eventually, the internal resistance will lead to a failure of a battery pack. Because all cells in the battery pack have the same problem, the pack internal resistance increases slowly over time, but not in a manner that causes concern. However, when compared to other packs manufactured at a different time the increase in internal resistance will be viewed as unusual, and thus indicative of a fault. This comparison is best performed at a location common to multiple battery packs, such as at external systems 1340 or IOT cloud 1350.
Upon identifying unusual behaviour of certain battery packs, the IOT Cloud 1350 may inform external system 1340. External system 1340 can a similar observation and decide to remove the battery packs of concern from operation, or reduce their duty cycle to reduce degradation, or simply notify relevant operator.
Process flows of
The cell group includes one or more cells. In some embodiments, the cell group includes a single cell, or a plurality of cells connected in parallel.
CMD 400 is operable to monitor the state of the cell group, including for any faults arising at one or more cells of the cell group by measuring one or more properties of one or more cells in the cell group or the cell group as a whole, or both. CMD 400 may be operable to measure electrical, physical, or chemical properties of one or more cells or the cell group, or any combination thereof, using corresponding sensors. CMD 400 may also be operable to measure properties of the environment surrounding the cell group using corresponding one or more sensors and use such measurements when evaluating the measurements obtained at the cell group for potential faults.
CMD 400 is local to the cell group. For example, CMD 400 may be attached to the cell group, incorporated with the cell group (e.g., incorporated with a housing hosting the cell group), integrated with or within a cell in the cell group, or otherwise connected to the cell group so as to monitor the state of cells in the cell group.
At step 1505, CMD 400 receives one or measurements obtained at the cell group by one or more sensors. As discussed, for example, with reference to
CMD 400 includes one or more cell models configured to receive sensor measurements as input and to output a result of determining whether corresponding one or more cells or the group of cells experienced a fault based on the inputted measurements. Example cell models are described elsewhere in this disclosure, for example, with reference to
As discussed with reference to
Upon determining a fault, CMD 400 may determine a severity level of the determined fault at step 1520. Details of classifying faults according to severity levels and various examples of both are described with reference to
At step 1525, CMD 400 stores locally, for example, in memory of CMD (such as fault store 426 or 626), a fault indicator indicating that the cell group experienced a fault, and related fault data. The fault data at least includes a timing information, such as a timestamp, indicating when the fault was determined by CMD 400. The fault data may also include sensor measurements (actual, derived, or a combination of both) that led CMD to determine the fault.
At step 1530, CMD 400 retrieves, from its memory, one or more fault indicators and related fault data, including the fault indicator and related fault data. As described, for example, with reference to
At step 1535, CMD 400 communicates the retrieved one or more fault indicators and related fault data to BMS or the external device. CMD 400 may also retrieve, from its memory, and communicate measurements of cell properties that have been obtained at the monitored cells but did not result in the CMD 400 detecting a fault.
Upon completion of step 1535, the method returns to step 1505.
In some embodiments, CMD 400 may store and communicate a fault indicator and related fault data in parallel, or communicate the fault indicator and related fault data prior to storing the same in memory of CMD 400.
Method 1600 starts with step 1605 at which BMS 430 requests status update on a cell group, from CMD 400 associated with the cell group. For example, as discussed with reference to
In some embodiments, CMD alerts BMS about a detected fault, upon detecting such a fault. Method 1600 may then start with BMS 430 receiving an alert from CMD 400 that CMD 400 detected a fault. For example, as discussed with reference to
In some embodiments, the alert may include or be accompanied by a fault indicator and fault data. In such embodiments, BMS 430 does not need to request CMD 400 for relevant data, and method 1600 instead starts with step 1610, which serves to alert BMS 430 that CMD 400 detected a fault.
Method 1600 may also start with step 1610, instead of step 1605, when CMD 400 transmits status updates, including fault indicator(s) and related fault data to BMS 430 according to a predefined schedule, as for example discussed with reference to
At step 1610, BMS 430 receives, from CMD 400, a fault indicator and related fault data. The fault indicator indicates that CMD 400 detected or determined a fault at the cell group based on measurement(s) obtained at the cell group by respective sensors of CMD 400. The fault indicator may also identify the fault, include a severity level of the fault, or both.
The fault data includes a timing information, such as a timestamp, indicating when CMD 400 determined the fault. The fault data may also include sensor measurement(s) obtained by CMD 400 at the cell group and used to determine the fault, measurements derived from the sensor measurement, or both. CMD 400 may send the fault indicator and related fault data responsive to the request sent by BMS 430 at step 1605.
The status update sent by CMD 400 may include all faults determined by CMD 400 at the cell group since the previous status update sent by CMD 400, all faults determined by CMD 400 at the cell group during a particular time period, all faults determined by CMD 400 at the cell group over the lifetime of CMD 400 or the cell group, or all faults determined by CMD 400 at the cell group while BMS 430 was powered off, or inactive, or otherwise incommunicado with CMD 400. The status update sent by CMD 400 may also include cell property measurements obtained during the same time periods or derivatives of such measurements, or both that did not result in CMD 400 detecting any faults.
At step 1615, BMS 430 processes the received fault indicator and related fault data to determine if an action responsive to the detected fault is needed. For example, the action may be BMS 430 updating the status of the battery system to fault condition and transmitting the data received from CMD 400 to an external system
As discussed with reference to
Alternatively or additionally, as also discussed with reference to
At step 1620, BMS 430 stores results of processing the received fault indicator and related fault data. For example, BMS 430 may update the status of the battery system to indicate that it experienced a fault or is in fault condition, a type of the fault, where the fault originated, and other relevant data. Additionally or alternatively, BMS 430 stores the received fault indicator and related fault data.
At step 1625, BMS 430 may receive, from an external system, a request for a status update on the battery system comprising the cell group. At step 1630, BMS 430 transmits results of processing the received fault indicator and related fault data and/or the fault indicator and related fault data received from CMD 400 to the external system.
The BMS may repeat steps 1605 to 1630 for all CMDs 400 monitoring the status of battery cells forming the battery system.
The descriptions of the various embodiments of the present disclosure have been presented for purposes of illustration and are not intended to be exhaustive or limiting to the scope of the disclosure. Many modifications and variations of the disclosed embodiments will be apparent to those of ordinary skill in the art from the herein disclosed embodiments, without departing from the scope of the disclosure. The terminology used herein to disclose the embodiments of the disclosure was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.
It is appreciated that certain features of the disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination or as suitable in any other described embodiment of the disclosure. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments unless the embodiment is inoperative without those elements.
Although the disclosure has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.
Further features of the disclosure are set out in the following clauses:
1. A method for monitoring a cell group by a cell monitoring device, CMD, the cell group comprising one or more battery cells, the method comprising:
2. The method of clause 1, wherein for each determined fault, the related fault data comprise at least one of: one or more sensor measurements the CMD used to determine the fault, or one or more derived measurements the CMD used to detect the fault.
3. The method of clause 1 or 2, wherein for each determined fault, the fault indicator identifies the fault.
4. The method of any of clauses 1 to 3, further comprising: determining, based on the received at least one measurement, a severity level of the first fault, the severity level being one of an immediate hazard, a delayed hazard, or a degradation hazard.
5. The method of clause 4, wherein determining the severity level of the first fault comprises:
6. The method of clause 4 or 5, wherein the fault indicator of the first fault identifies the severity level of the first fault.
7. The method of any of clauses 1 to 6, comprising:
8. The method of any of clauses 1 to 7, comprising:
9. The method of clause 8, wherein the receiving, processing, and storing steps are repeated by the CMD independent of the BMS or the external device.
10. The method of any of clauses 7 to 9, wherein the receiving and processing steps are repeated with a varied frequency depending at least on one of: whether the CMD is in a first mode or a second mode, or a type of at least one measurement.
11. The method of any of clauses 1 to 10, wherein determining the first fault comprises: processing a sequence of measurements obtained by the at least one sensor at the cell group and determining by the CMD relative to a corresponding cell model of the cell group that the cell group experienced a fault based on a predefined number of measurements in the sequence.
12. The method of any of clauses 1 to 11, wherein communicating to the BMS comprises: in response to determining the first fault, transmitting an alert by the CMD to the BMS; and
13. The method of clause 12, wherein the status update is transmitted in response to a request received from the BMS.
14. The method of clause 12 or 13, wherein the alert is a signal configured to cause the BMS to transition from one mode to another mode.
15. The method of any of clauses 12 to 14, wherein the alert is transmitted by the CMD to the BMS when the detected first fault is determined to have a severity level of an immediate hazard.
16. The method of any of clause 1 to 11, wherein communicating to the BMS comprises:
17. The method of any of clauses 12 to 16, wherein the status update comprises the one or more fault indicators and the related fault data concerning one of:
18. The method of any of clauses 1 to 17, wherein the first fault is an operational fault, the operational fault being determined by the CMD when performance of the cell group is determined to fall outside of a safe operating area defined by predetermined safe operational limits or outside of a normal operating area defined by predetermined normal operational limits, wherein the safe and normal operational limits correspond to the obtained measurements and defined by the at least one cell model of the cell group.
19. The method of clause 18, wherein the operational fault is determined when the at least one measurement obtained at the cell group meets at least one of the following conditions:
20. The method of any of clauses 1 to 17, wherein the first fault is a behavioural fault, the behavioural fault being determined when performance of the cell group deviates from expected performance of the cell group by a deviation greater than a predefined threshold, the expected performance of the cell group being defined by:
21. The method of clause 20, wherein the behavioural fault is determined when the at least one measurement obtained at the cell group meets at least one of the following conditions:
22. The method of clause 20 or 21, comprising:
23. The method of any of clauses 1 to 22, wherein the at least one sensor comprises one or more of: a sensor adjacent to the cell group, a sensor located at the cell group, a sensor located within the cell group, a sensor incorporated with the cell group, a sensor located on one or more battery cells of the cell group, a sensor located incorporated with one or more battery cells of the cell group.
24. The method of any of clauses 1 to 23, wherein the at least one sensor comprises a sensor configured to measure an electric, chemical, or physical property of a battery cell in in the cell group and a different sensor configured to measure an electric, chemical, or physical property of the cell group.
25. The method of any of clauses 1 to 24, where the at least one sensor comprises one or more of:
26. The method of any of clauses 1 to 25, comprising:
27. A computer-readable medium storing instructions which, when executed by a processor of a cell monitoring device, cause the cell monitoring device to perform the method of any of clauses 1 to 26.
28. A circuitry configured to execute functions for causing a cell monitoring device to perform the method of any of clauses 1 to 26.
29. A cell monitoring device, CMD, configured for assembly with a cell group comprising one or more battery cells, the CMD comprising:
30. The CMD of clause 29 configured to operate in a first mode and a second mode, wherein the CMD is configured to receive and process measurements obtained by the at least one sensor at the cell group to determine whether the cell group experienced a fault less frequently while operating in the first mode than while operating in the second mode.
31. A method for monitoring a battery by a battery management system, BMS, the battery comprising a plurality of cell groups, each cell group comprising one or more battery cells, and a cell monitoring device, CMD, of the cell group, the method comprising:
32. The method of clause 31, comprising:
33. The method of clause 31 or 32, wherein the fault data comprises one or more sensor measurements used by the first CMD to determine the fault.
34. The method of any of clauses 31 to 33, wherein the fault indicator identifies at least one of: the fault or a severity level of the fault, the severity level being one of an immediate hazard, a delayed hazard, or a degradation hazard.
35. The method of any of clauses 31 to 34, comprising:
36 The method of any of clauses 31 to 35, wherein processing the fault indicator and the related fault data comprises:
analysing the received fault data using a corresponding cell model stored at the BMS to confirm that the first cell group experienced the fault.
37. The method of any of clauses 31 to 36, wherein processing the fault indicator and the related fault data comprises:
38. The method of clause 37, wherein the one or more second cell groups are cell groups adjacent to the first cell group or the remaining cell groups in the plurality of cell groups.
39. The method of any of clauses 31 to 38, wherein the fault indicator indicating that the first CMD determined that first cell group experienced a fault and the related fault data are received from the first CMD of the first cell group as a part of a status update transmitted by the first CMD to the BMS, wherein the status update is received by the BMS periodically, at a prescheduled time, or in response to a status update request sent by the BMS to the first CMD.
40. The method of clause 39, wherein the status update of the first CMD comprises one or more fault indicators and related fault data concerning one of:
41. The method of any of clauses 31 to 38, wherein the BMS is in an inactive mode prior to receiving the fault indicator and the related fault data from the first CMD, the method comprising:
42. The method of any of clause 41, wherein fault determined by the first CMD is classified by the CMD as an immediate hazard.
43. The method of clause 41 or 42, wherein the wake-signal is accompanied by the fault indicator, and related fault data, thereby the wake-signal, the fault indicator, and related fault data are received by the BMS from the first CMD while the BMS is in the inactive mode.
44. The method of clause 41 or 42, comprising:
45. The method of any of clauses 31 to 44, wherein the fault determined at the first cell group is an operational fault, the operational fault being determined when performance of the first cell group is determined to fall outside of a safe operating area defined by predetermined safe operational limits or outside of a normal operating area defined by predetermined normal operational limits, wherein the safe and normal operational limits correspond to the measurements obtained at the first cell group and are defined by a cell model corresponding to the first cell group.
46. The method of clause 45, wherein the operational fault is determined when the measurements obtained at the first cell group meet one or more of conditions:
47. The method of any of clauses 31 to 44, wherein the fault determined at the first cell group is a behavioural fault, the behavioural fault being detected when performance of the first cell group deviates from expected performance of the first cell group by a deviation greater than a predefined threshold, the expected performance of the first cell group being defined by at least one of: a cell model corresponding to the first cell group or performance of one or more neighbouring cell groups in the plurality of cell groups determined based on measurements obtained by sensors at the one or more neighbouring cell groups.
48. The method of clause 47, wherein the behavioural fault is determined when the measurements obtained at the first cell group meet at least one of the following conditions:
49 The method of clause 47 or 48, comprising:
50. The method of any of clauses 37 to 49, the measurements obtained at the first cell group and received by the BMS as the fault data comprise one or more of: a voltage detected at the first cell group, a temperature detected externally to the cell group, a temperature at the first cell group, a temperature at a cell or within the cell of the first cell group, a gas pressure within a cell of the first cell group, a force exerted by a cell of the first cell group on an external surface of the cell, a deflection of a cell enclosure of a cell in the first cell group caused by a change of internal pressure, a humidity level at the first cell group or at a cell in the first cell group, a predetermined chemical indicative of cell damage, or a current flowing through the first cell group or through a cell in the first cell group.
51. A computer-readable medium storing instructions which, when executed by a processor of BMS, cause the BMS to perform the method of any of clauses 31 to 50.
52. A circuitry configured to execute functions for causing a Battery Management System, BMS, to perform the method of any of clauses 31 to 50.
53. A battery management system configured to communicate with cell monitoring devices in a battery, the battery comprising a plurality of cell groups, each cell group comprising one or more battery cells, and a cell monitoring device of the cell group, the BMS comprising:
54. A method for monitoring a battery by a battery management system, BMS, the battery comprising a plurality of cell groups, each cell group comprising one or more battery cells and a corresponding cell monitoring device, CMD, the method comprising:
55. The method of clause 54, comprising:
56. The method of clause 54 or 55, wherein the fault data comprises at least one measurement used by the first CMD to determine the fault, the at least one measurement comprising one or more of a measurement obtained at the first cell group or a measurement derived based on one more measurements obtained at the first cell group.
57. The method of any of clauses 54 to 56, wherein the fault indicator indicates one or more of: the fault or a severity level of the fault, the severity level being one of an immediate hazard, a delayed hazard, or a degradation hazard.
58. The method of any of clauses 54 to 57, wherein processing the received fault indicator and fault data comprises storing, at the BMS, the fault indicator and the related fault data received from the first CMD, the method comprising:
59. The method of any of clauses 54 to 58, wherein processing the received fault indicator and fault data comprises:
60. The method of any of clauses 54 to 59, wherein processing the received fault indicator and fault data comprises:
61. The method of clause 60, comprising:
62. The method of clause 60 or 61, wherein the second cell group comprises one or more cells adjacent to the first cell group or wherein the method comprises repeating the receiving and comparing steps for each cell group of the plurality of cell groups.
63. The method of any of clauses 54 to 62,
64. The method of any of clauses 54 to 63, wherein the BMS is in a sleep mode prior to receiving the fault indicator and the related fault data from the first CMD, the method comprising:
65. The method of clause 64, comprising:
66. The method of any of clauses 54 to 65, the measurements obtained at the first cell group and received by the BMS as the fault data comprise one or more of:
67. The method of any of clauses 54 to 66, wherein the fault determined at the first cell group is an operational fault or a behavioural fault,
68. The method of clause 67,
69. The method of clause 67, comprising:
70. A circuitry configured to execute functions for causing a Battery Management System, BMS, to perform the method of any of clauses 54 to 69.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21183301.7 | Jul 2021 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/067995 | 6/29/2022 | WO |
