The present disclosure relates to detecting isolation for a rechargeable energy storage system (RESS), such as but not necessarily limited to determining a loss of isolation for a RESS included onboard a vehicle to store and supply electrical power for a traction motor.
A rechargeable energy storage system (RESS) may be configured for storing and supplying electrical power, with one of the more common types of RESSs including a plurality of battery cells arranged into one or more battery packs. Such RESSs may be included onboard a vehicle to store and supply electrical power for a traction motor operable for converting the electrical power to mechanical power for purposes of propelling the vehicle. To achieve desired levels of operation, it may be advantageous to electrically isolate one or more of the battery packs from another one or more of the battery packs. Because of the advantages associated with maintaining electrical isolation, it may be desirable to detect when a loss of the electrical isolation may have occurred or may be likely to occur so that corrective action may be taken.
One non-limiting aspect of the present disclosure relates to detecting a loss of isolation for a rechargeable energy storage system (RESS). The systems and methods described herein may be operable for detecting a loss of isolation for a wide variety of RESSs, including RESSs of the type having a plurality of battery cells arranged into one or more battery packs to store and supply electrical power for a traction motor of a vehicle. The loss of isolation may be determined based on systematic processes for monitoring and tracking isolation resistance signals to predict a loss of isolation using statistical models, machine learning, and/or physics-based algorithms for isolation loss prediction and isolation type identification.
One non-limiting aspect of the present disclosure relates to a system to detect/predict high voltage battery pack isolation loss and provide isolation type identification. The system may utilize RESS isolation resistance, temperature, and/or a combination of features to enable accurate detection, identification, and robust to noise resistance determinations based on a variety of factors. The system may monitor a fleet of vehicles to learn nominal bounds, signature patterns sufficient to isolate between coolant leak/water intrusion and cell corrosion, to provide insights on isolation causes, to monitor isolation loss progression and send proactive alerts/notifications to warn customers ahead of time, and/or to manage vehicle operation. The system may optionally be implemented using a passive approach such that attendant detection may occur while the vehicle is in operation and optionally without impacting driving.
One non-limiting aspect of the present disclosure relates to a system for assessing loss of isolation for a rechargeable energy storage systems (RESS). The system may include a data collection module configured for determining isolation resistance data for a plurality of RESSs operating onboard a fleet of vehicles, optionally with the RESSs configured to store and supply electrical power for a traction motor of the vehicle associated therewith. The system may further include an intelligent filtering and reprocessing module configured for applying statistical methods and engineering rules to remove erroneous peaks and duplicate values from the isolation resistance data. The system may further include a prognostic module configured for generating isolation rules from healthy data included with the isolation resistance data, optionally with the isolation rules operable assessing whether the isolation resistance data is representative of a loss of isolation. The system may further include an assessment module configured for characterizing each loss of isolation.
The prognostic module may be configured for generating the isolation rules to include thresholds for determining whether the loss of isolation has occurred.
The assessment module may be configured for applying the isolation rules to the isolation resistance data to identify an isolation issue type for the RESSs determined to have the loss of isolation.
The assessment module may be configured for determining the isolation issue type to correspond with a water intrusion event when the isolation resistance data exceeds a water intrusion resistance signature included as one of the isolation rules.
The assessment module may be configured for determining the isolation issue type to correspond with a cell corrosion event when the isolation resistance data exceeds a cell corrosion resistance signature included as one of the isolation rules.
The intelligent filtering and reprocessing module may be configured for performing a multiple pack processing, optionally with the multiple pack processing removing the isolation resistance data associated with each RESS having multiple packs showing similar erroneous behavior.
The prognostic module may be configured for performing distribution fitting and threshold learning to generate control limits and prognostic thresholds for the fleet.
The assessment module may be configured for employing a severity index and a severity assessment to determine a severity and provide an early warning to a customer of each vehicle having the loss of isolation.
The system may include an alert module configured for transmitting an alert to an operating system onboard each vehicle to be provided the early warning.
The alert module may be configured for generating the alert to include instructions to request an operator to service the vehicle associated therewith.
The alert module may be configured for generating the alert to notify an operator of the vehicle associated therewith that a shutdown command has been issued to prevent further use of the RESS associated therewith.
One non-limiting aspect of the present disclosure relates to a method for assessing loss of isolation for a rechargeable energy storage systems (RESS). The method may include collecting isolation resistance data for a plurality of RESSs operating onboard a fleet of vehicles, optionally with each RESS operating onboard a vehicle to store and supply electrical power for a traction motor, applying statistical methods and engineering rules to remove erroneous peaks and duplicate values from the isolation resistance data, generating one or more isolation rules based on the isolation resistance data, optionally with the isolation rules representing thresholds for determining whether a loss of isolation has occurred, applying the isolation rules to the isolation resistance data to identify one or more of the RESSs having an isolation issue, and identifying an isolation issue type for the RESSs determined to have the isolation issue.
The method may include determining the isolation issue type to correspond with a water intrusion event when the isolation resistance data exceeds a water intrusion resistance signature included as one of the isolation rules.
The method may include determining the isolation issue type to correspond with a cell corrosion event when the isolation resistance data exceeds a cell corrosion resistance signature included as one of the isolation rules.
The method may include deriving graphical representations of the isolation resistance data as signatures operable to correspondingly represent operations of the RESSs operating in a healthy manner and an unhealthy manner.
The method may include performing peak filtering on the isolation resistance data according to engineering rules to remove erroneous peaks from the graphical representations.
The method may include transmitting an alert to an operating system onboard one or more of the vehicles determined to have the isolation issue.
The method may include including instructions in the alert to request an operator to service the vehicle associated therewith.
The method may include including instructions in the alert to notify the operator that a shutdown command has been issued to prevent further use of the RESS associated therewith.
One non-limiting aspect of the present disclosure relates to a system for assessing loss of isolation for rechargeable energy storage systems (RESSs). The system may include a data collection module configured for determining isolation resistance data for a plurality of RESSs, optionally with the RESSs configured to store and supply electrical power for a traction motor of a vehicle associated therewith. The system may further include an intelligent filtering and reprocessing module configured for generating filtered isolation resistance data by applying statistical methods and engineering rules to remove erroneous peaks and duplicate values from the isolation resistance data. The system may further include a prognostic module configured for generating a water intrusion signature and a cell corrosion signature based on the filtered isolation resistance data, optionally with the water intrusion signature representing characteristics associated with a water intrusion type of isolation loss and the cell corrosion signature representing characteristics associated with a cell corrosion type of isolation loss, and determining whether a loss of isolation has occurred for one or more of the RESSs based at least in part on determining whether the water intrusion and/or cell corrosion signatures match with the isolation data associated therewith.
These features and advantages, along with other features and advantages of the present teachings, may be readily apparent from the following detailed description of the modes for carrying out the present teachings when taken in connection with the accompanying drawings. It should be understood that even though the following figures and embodiments may be separately described, single features thereof may be combined to additional embodiments.
The accompanying drawings, which may be incorporated into and constitute a part of this specification, illustrate implementations of the disclosure and together with the description, serve to explain the principles of the disclosure.
As required, detailed embodiments of the present disclosure may be disclosed herein; however, it may be understood that the disclosed embodiments may be merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures may not be necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein may need not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present disclosure.
The vehicle 12 may include a vehicle controller 34 to facilitate monitoring, controlling, measuring, and otherwise directing operation, performance, etc. onboard the vehicle 12, which may include performing measurements, taking readings, or otherwise collecting RESS data from the RESS 30. The system 10 may include an isolation detection controller 36 at a back office or other location operable for communicating with the fleet of vehicles 12, such as via wireless signal exchange with corresponding controllers 34. The isolation detection controller 36 may be configured for performing a wide variety of operations, processes, etc. to facilitate the loss of isolation detection contemplated herein. The isolation detection controller 36 and the vehicle controller 34 may each operate based on and/or according to a corresponding one or more processors executing a corresponding plurality of non-transitory instructions stored on an associated computer-readable storage medium. The non-transitory instructions may be executable for purposes of communicating messages, executing software or other algorithms, performing calculations, and otherwise facilitating exchange of data with the vehicles 12 to perform the various activities described herein to detect loss of isolation. The operation of the isolation detection controller 36 may be allocated to a data collection module 40, an intelligent filtering and reprocessing module 42, a prognostic module 44, and an assessment module 46.
Block 54 relates to a filtering process whereby the intelligent filtering and reprocessing module 42 may apply statistical methods and engineering rules to remove erroneous peaks and/or duplicate values from the isolation resistance data. The filtering process may include the intelligent filtering and reprocessing module 42 receiving the isolation resistance data from the data collection module 40 and processing the isolation resistance data into filtered isolation resistance data having duplicate values, erroneous peaks, etc. removed.
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While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims. Although several modes for carrying out the many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and exemplary of the entire range of alternative embodiments that an ordinarily skilled artisan would recognize as implied by, structurally and/or functionally equivalent to, or otherwise rendered obvious based upon the included content, and not as limited solely to those explicitly depicted and/or described embodiments.