This invention relates to inductive cell balancing, in multiple-cell power supply applications. The cells can be battery cells or capacitor (super capacitor) cells. One example of particular interest is the cells used in electric vehicle battery packs.
In (hybrid) electric vehicles, large numbers of series-connected batteries are used to generate a high voltage to drive the motor. For optimum life time of the battery cells (and drive range of the car), the State of Charge (SoC) of all battery cells should always be the same. When the cells in a series-connected string are charged they all receive the same current, so in principle they should be at the same SoC after charging. There are, however, always mismatches between battery cells, e.g. leakage current and efficiency of converting current into chemically stored energy. Therefore the SoCs of the battery cells will not be the same after charging. If nothing is done, the differences will grow with each charge/discharge cycle.
To keep the SoC of all battery cells as equal as possible cell-balancing circuits are usually added to the high-voltage battery pack of (hybrid) electric cars.
In this application, the following words are used to describe the various parts of a high-voltage battery pack.
A “pack” or “battery pack” 18 is a group of parallel-connected slices 16 that make up the total battery as used in the application. The parallel connection increases the energy content and power capabilities of the battery pack, but not its voltage. In many applications the battery pack 18 consists of just one single slice 16. Depending on the application, the voltage is somewhere in the range of 100V to 600V (same as the slice voltage).
For electric vehicles without internal combustion engine, the approaches of
Two sections 12a, 12b share one battery cell 50, the highest cell of one section 12b serves as the lowest cell of the next section 12a (by “next” section is meant the next section at a higher voltage). The other components are not shared between sections.
In general, the lowest cell of the section M is also the highest cell of section M−1. Applying this rule, arbitrarily long chains can be created. The system of
The system of
A particular problem with the inductive solution compared to resistive solutions is the cost of the components.
There is therefore a need for a cell balancing approach which finds a balance between circuitry cost and efficiency.
According to the invention, there is provided an energy storage cell arrangement comprising:
a series arrangement of cells, comprising at least two cells;
an inductor; and
a switching arrangement,
wherein the switching arrangement is controllable such that it is able to couple one side of the inductor to any one of a first set of cell terminals, and to couple the other side of the inductor to any one of a second set of cell terminals, wherein the first and second sets of cell terminals together comprise all cell terminals of the series arrangement.
This arrangement enables the inductor, used for energy transfer between cells, to be shared between cells.
In a first set of embodiments, the cell terminals of the first set are different to those of the second set. This provides the smallest number of connections to enable any cell terminal to be coupled to one or other terminal of the inductor.
In one arrangement, the switching arrangement can comprise a respective switch between each cell terminal and one of the inductor terminals, and a respective diode in parallel with each switch. This provides an arrangement with a switch and diode for each cell terminal, thus providing a small amount of additional circuitry.
In another arrangement, the switching arrangement comprises a respective switch between each cell terminal and one of the inductor terminals, a respective diode between each inductor terminal and the top cell terminal and a respective diode between each inductor terminal and the bottom cell terminal. This arrangement needs only four diodes.
In another arrangement, the switching arrangement comprises a first three-way switch at the input to one of the inductor terminals, a second three-way switch at the input to the other of the inductor terminals, and a respective switch between each cell terminal and both of the three-way switches, wherein the three way switches are controlled such that each respective switch is connected to one or other of the inductor terminals. In this case, the switching arrangement can comprise a first diode between the one inductor terminal and the top cell terminal and a second diode between the other inductor terminal and the bottom cell terminal.
This arrangement needs only two diodes, at the expense of having more switches in the circuit.
In a second set of embodiments, the cell terminals of the first set can include all cell terminals and the cell terminals of the second set can include all cell terminals. This provides most flexibility, in that all cell terminals can be connected to either inductor terminal.
In one arrangement, the switching arrangement comprises a respective switch between each cell terminal and one of the inductor terminals, a respective switch between each cell terminal and the other of the inductor terminals, and a respective diode between the one inductor terminal and the top cell terminal and a respective diode between the other inductor terminal and the bottom cell terminal. This arrangement requires only two diodes, but has two switches associated with each cell terminal.
In another arrangement, the switching arrangement comprises a respective diode between each inductor terminal and the top cell terminal and a respective diode between each inductor terminal and the bottom cell terminal.
The arrangement can further comprise a controller adapted to:
identify a cell or cells from which charge is to be removed;
control the switching arrangement to transfer energy from the identified cell or cells to the inductor; and
control the switching arrangement to transfer energy from the inductor to another cell or cells.
This control of the switching enables a desired transfer of energy between cells.
The invention also provides an electric vehicle battery cell pack comprising one or more battery cell arrangements of the invention.
The invention also provides a method of performing cell balancing within an energy storage cell arrangement which comprises a series arrangement of cells, comprising at least two cells and an inductor shared between all cells, the method comprising
identifying a cell or cells from which charge is to be removed;
controlling a switching arrangement to transfer energy from the identified cell or cells to the shared inductor; and
controlling the switching arrangement to transfer energy from the inductor to another cell or cells.
Examples of the invention will now be described in detail with reference to the accompanying drawings, in which:
The same reference numbers have been used in different figures to denote the same components. The circuit diagrams in the figures present modifications compared to the previous circuits described, and for this reason, a description of the common components is not repeated.
The invention provides an energy storage cell arrangement in which a shared inductor is used. A switching arrangement is controllable such that it is able to couple one side of the inductor to any one of a first set of cell terminals, and to couple the other side of the inductor to any one of a second set of cell terminals, wherein the first and second sets of cell terminals together comprise all cell terminals of the series arrangement. In this way, energy can be transferred between cells in a configurable way, using a shared inductor.
In
Thus, there are 2N switches, where N=no. of cells+1.
A respective diode 66a is connected between the one inductor terminal 64a and the top cell terminal 68. A respective diode 66b is connected between the other inductor terminal 64b and the top cell terminal 68. A respective diode 66c is connected between the one inductor terminal 64a and the bottom cell terminal 70. A respective diode 66d is connected between the other inductor terminal 64b and the bottom cell terminal 70.
The diodes provide a current path to the series of cells so that inductor current is maintained flowing even if all the switches are open. The diode orientation is such that the cells cannot discharge through the diodes. Thus, the circuit made from the diodes and cells has the diodes and cells in a loop with the diodes reverse biased by the cell voltage.
The inductor in
If the current is not allowed to drop to zero, the circuit will start to act like a combination of an energy pump and a charge pump. If the switching frequency is so high that a DC current flows through the coil, then the circuit operates as a pure charge pump.
Path 80 shows the discharge of the highest charged cell, which in this case is the top cell. This builds flux in the inductor. For this purpose, one switch couples the top cell terminal to the inductor terminal 64a and another switch couples the second cell terminal down to the inductor terminal 64b.
When the switches in the path 80 are opened, the inductor will react by forcing current through the path 82. Path 82 shows the spill-over during switching from discharging to charging, and it drives current through the diodes.
Path 84 shows the path for inductor current to flow through the bottom cell. For this purpose, one switch couples the bottom cell terminal to the inductor terminal 64a and another switch couples the second cell terminal up to the inductor terminal 64b.
As soon as the switches in the path 84 are closed the inductor current will flow through the bottom cell.
Normally the time between opening the switches in path 80 and closing the switches in path 84 will be chosen as short as possible as the current path 82 pushes charge in all cells. As the target was to transfer energy from the top cell to the bottom cell, this can be regarded as a kind of spill-over. The energy in the red path 82 is not lost, as it transferred to all three cells, but it reduces the effective transfer of energy form the top cell to the bottom cell.
However, there is no reason why the spill-over path cannot be used on purpose—to transfer charge from the inductor to all cells. A designer can choose to take energy from one, two, or three cells and dump that energy in one, two, or three cells. The circuit offers all the flexibility needed to do this.
In this case, there is only one diode 85 (or diode chain) between the one inductor terminal 64a and the top cell terminal 68 and one diode 86 (or diode chain) between the other inductor terminal 64b and the bottom cell terminal 70.
The current in the inductor has to return to zero before the next packet of energy can be moved from one cell to another. It is therefore possible to choose the direction of the current in the inductor each time a new energy transfer cycle is started. If the current in the inductor 60 always flows in the same direction, the same two diodes will always carry the spill-over current. In this way, the other two diodes can be eliminated from the circuit without any penalty.
The desired current flow can be assured by connecting the inductor with the correct polarity.
The circuit of
The switching arrangement comprises a first three-way switch 90 at the input to one of the inductor terminals 64a, a second three-way switch 92 at the input to the other of the inductor terminals 64b, and a respective switch 94 between each cell terminal and both of the three-way switches. The three way switches 90,92 are controlled such that each switch 94 is connected to or one other of the inductor terminals.
This means that only one switch 94 is needed between the cell terminal and the three way switches 90,92.
A first diode is between the one inductor terminal 64a and the top cell terminal 68 and a second diode is between the other inductor terminal 64b and the bottom cell terminal 70.
In the circuit of
The toggle switches 90,92 and the switches 94 are in series, and
As is clear from the description above,
In
A respective diode is between each inductor terminal and the top cell terminal and a respective diode is between each inductor terminal and the bottom cell terminal (i.e. the same diode arrangement as in
This has reduced flexibility—for example a pair of adjacent cells cannot be switched as a single unit. However, there is a reduction in number of switches.
In
The circuits of
The inductor of
The table below gives an overview of the number of components it takes to balance a battery pack with N cells, for various different embodiments above:
The table shows that the circuit of
In this way, it is very easy to bring down the cost of an existing cell balancer by removing all inductors from the circuit and re-inserting half of them in a different position.
A first disadvantage is that the worst case balancing time of
Secondly, the efficiency of
The table below shows the number of components in a battery pack with N cells built with M-cell sections, which together make up the N cells.
For example with 9 cells, there are four sets of 3 cells, with cells 3 and 57 overlapping between pairs of cell sections. Thus N=9, M=3 and 4 inductors are needed ((N−1)/(M−1)=4). The same overlap between cell sections explains the figures for switches and diodes.
As mentioned above, it is important to pump energy, not charge, to achieve maximum efficiency. To this end the inductor current must have returned to zero before the start of each new pump cycle. The diodes help keep the current in the inductor at zero at the end of a pump cycle. However, due to the forward voltage of the diode it always dissipates some power while current is flowing through it. This energy is lost in the pumping process. To keep the efficiency of the energy pump as high as possible the voltage drop across the diode must be as low as possible. This can easily be achieved by using a Schottky diode. A disadvantage of a Schottky diode is that it is an extra component, i.e. a cost adder. A cheaper solution is to use the transistor body diodes of the switches. These, however, have a higher forward voltage than a Schottky diode.
Another approach to keeping the efficiency high is to turn on the switch of the diode that is conducting the flyback current. When the switch is on the diode will, in effect, not conduct any current as all current will flow through the switch. With a low-ohmic switch the losses will be very low.
A new problem is then that if the switch is not turned off when the current is zero, a reverse current will start flowing through the inductor. This will change the character of the pump to be something between an energy pump and a charge pump. This is bad for efficiency. This can be solved by measuring the voltage across the switch and switching it off when it is zero. A disadvantage of this approach is that it is costly as an extra comparator is needed.
A better approach is to use the fact that energy is always pumped from a higher-charged to a lower-charged cell. This is equivalent to pumping from a higher-voltage to a lower-voltage cell (assuming the cells have the same temperature). Per unit time the current change in the inductor is higher when connected to the highest-charged cell. If the switch across the flyback diode is kept closed exactly as long as the switch that connects the inductor to the highest-charged cell, the current in the inductor will still be (slightly) higher than zero by the time the switch is opened across the flyback diode. The flyback diode now only has to conduct the “tail” of the flyback current.
As the energy in the tail is very low, this does not have a major impact on the efficiency, even if the switch's transistor body diode is used instead of a Schottky diode. In a practical circuit the “flyback switches” will be closed slightly shorter than “pump switches”. This to make sure that parasitic effects do not cause a reversal of the current in the inductor.
The left set of plots shows the case where the second phase is carried out without using flyback switching as explained above.
Initially, transistors T1 and T2 are turned on, and the inductor current rises, sourced from the top cell. T1 is then turned off. The inductor current then flows to the second cell through the diodes D2, D3. The second cell, the diodes D2 and D3 and the inductor from a closed circuit. Transistor T2 is shown turned on during this time but the current flow (in the reverse direction) is through the diode D2. All transistors are off before the next cycle begins.
The right set of plots shows the case where the second phase is carried out using flyback switching as explained above. In the second phase (energy transfer to the second cell), the transistor T3 is turned on for the initial part of the inductor current timing. This means that current flow is through the transistor T3 (in the forward direction) rather than through diode D3 while T3 is turned on. Only the small inductor current tail is driven through diode D3.
Circuits for the measurement of cell voltage for use in cell balancing are already known and in use, and these do not need any modification for use in the invention. They form part of a control circuit for the section, and such a control circuit (as can be used to implement the invention) is shown schematically in
In all circuits discussed, a cell can be replaced by a group of cells. This means it is fairly easy to make a hierarchical cell-balancing system. In the lowest level sections composed of battery cells are balanced, in the highest level sections of battery modules are balanced. The circuit topologies are the same, but the specification of the components of the different levels are, of course, very different as the voltage of a module is roughly ten times the voltage of a cell.
The techniques described in this document can also be applied to super capacitors instead of battery cells.
Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.
Number | Date | Country | Kind |
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10167520.5 | Jun 2010 | EP | regional |
10189210.7 | Oct 2010 | EP | regional |