Abstract:
The present invention discloses a battery pack which can be used for an electric vehicle, an Uninterrupted Power Supply (UPS), and a power supply for a smart grid and which can be easily manufactured and repaired and which is capable of improving productivity, the span of life, and performance, and a battery management system including the battery pack.
       The battery pack of the present invention comprises a casing in which a reception space is provided and battery modules coupled to the casing at regular intervals by fastening members so that the battery modules can be easily dismantled from the casing. Each of the battery modules includes a tray, a battery cell provided in the tray, a cell charger provided in the tray and configured to charge the battery cell, a cell controller provided in the tray and configured to control the cell charger, a heating mat coupled to the battery cell, and a temperature sensor provided in the tray and configured to sense a temperature of the battery cell.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to and the benefit of Korean Patent Application Nos. 10-2009-0117165, 10-2010-0006630, 10-2010-0012741, and 10-2010-0033934 filed in the Korean Intellectual Property Office on Nov. 30, 2009, Jan. 25, 2010, Feb. 11, 2010, and Apr. 13, 2010, the entire contents of which are incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     (a) Field of the Invention 
     The present invention relates to a battery pack and a battery management system including the same. More particularly, the present invention relates to a battery pack which can be used for an electric vehicle, an Uninterrupted Power Supply (UPS), and a power supply for a smart grid and which can be easily manufactured and repaired and which is capable of improving productivity, the span of life, and performance, and a battery management system including the battery pack. 
     (b) Description of the Related Art 
     In general, a charging battery can be used as a driving source for an electric vehicle and as an UPS which can supply a stable power by overcoming a power failure which can occur in a common power. The battery can also be used as a power supply for a smart grid. 
     The battery has a battery pack type in which a plurality of battery cells is integrally interconnected depending on its capacity. 
     In the existing battery pack, when the battery pack is charged, the cells constituting the battery             are coupled in series or in parallel and then charged through one charger, and a deviation between the cells is manually managed. Accordingly, the existing battery pack is problematic in that the life span of the battery pack is reduced because of the deviation.
     Further, the existing battery pack has an assembly type in which each of the battery cells cannot be separated from the battery pack. Accordingly, there are problems in that if any one of the battery cells is faulty, the entire battery pack cannot be used, the life span is shortened, and a waste of resources is increased. 
     The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art. 
     SUMMARY OF THE INVENTION 
     The present invention has been made in an effort to provide a battery pack and an active cell-balancing battery management system including the same, having advantages of preventing deterioration in the performance of the battery pack and a reduction in the life span due to a deviation between cells in such a way as to connect a charger to each of the cells and to actively manage the deviation between the cells by individually managing the charging of the cells. 
     Further, the present invention has been made to provide a battery pack in which battery cells constituting the battery pack are fabricated in a replacement form, thereby enabling easy maintenance and repair and being capable of increasing the life span of the battery pack, and a battery management system including the battery pack. 
     Further, the present invention has been made to provide a battery pack in which a cell grading process can be omitted from a process of manufacturing battery cells, thereby being capable of simplifying a battery pack manufacture process and reducing the production cost, and a battery management system including the battery pack. 
     Further, the present invention has been made to provide a battery pack having a structure in which battery cells can be individually charged, thereby being capable of preventing charging imbalance in the battery cells which can occur in a conventional serial charging method or passive cell-balancing method, of increasing the life span of the battery pack, and of maximizing an available capacity of the battery pack, and a battery management system including the battery pack. 
     An exemplary embodiment of the present invention provides a battery pack, comprising a casing configured to include a reception space, trays coupled to the casing at regular intervals, battery cells provided in the respective trays, cell chargers respectively configured to charge the battery cells and provided in the trays, cell controllers respectively provided in the trays and configured to control the cell chargers, heating mats coupled to the respective battery cells, and temperature sensors respectively provided in the trays and configured to sense temperatures of the battery cells. 
     The casing preferably is equipped with guide slots having faced each other in pairs at regular intervals and having the trays fit and inserted into the guide slots. The trays each preferably are equipped with extension portions, the extension portions provided on both sides of the tray and inserted into the guide slots. 
     The trays each preferably are fastened to the casing using fastening members. 
     The cell controllers preferably are equipped with a communication connector connected to a main controller and configured to exchange data with the main controller. 
     Further, the present invention provides a battery management system, comprising: 
     a battery pack, comprising a casing configured to include a reception space, trays coupled to the casing at regular intervals, battery cells provided in the respective trays, cell chargers respectively configured to charge the battery cells and provided in the trays, cell controllers respectively provided in the trays and configured to control the cell chargers, heating mats coupled to the respective battery cells, and temperature sensors respectively provided in the trays and configured to sense temperatures of the battery cells; and 
     a main controller comprising a charging control module for receiving information about a state of charge (SOC) of each of the battery cells from the cell controllers and for controlling each of the cell chargers. 
     The main controller preferably further comprises a temperature control module for receiving signals corresponding to values measured by the temperature sensors and for controlling heating mats or a cooling fan for controlling a temperature of the battery cells. 
     The main controller preferably further comprises a battery cell protection control module connected to a current sensor for sensing currents of the battery cells and a current breaking switch for breaking the currents of the battery cells and configured to control the current breaking switch based on a signal received from the current sensor. 
     The main controller preferably further comprises a cell grading control module configured to perform cell grading for determining an inappropriate battery cell by determining a state of charge (SOC) and a state of health (SOH) of each of the battery cells in response to each of signals received from the cell controllers. 
     The cell grading control module preferably is further configured to determine the remaining life span of the battery cell by determining a state of charge (SOC) and a state of health (SOH) of each of the battery cells based on the signal received from the cell controller. 
     The main controller preferably comprises a communication control module configured to send data pertinent to the battery cells, received from the cell controllers, and data processed in relation to the data, received from the cell controllers, to an external memory and to communicate the data to an external computer. 
     The main controller preferably comprises a CAN communication port, a TCP/IP communication port, and a USB communication port. 
     Internal memories preferably are connected to the respective cell controllers, and the main controller preferably comprises a history management control module for recording histories of the battery cells in the respective internal memories and managing the histories. 
     In accordance with the exemplary embodiments of the present invention, the battery pack is configured to easily replace a battery module including a run-down or abnormal battery cell. Accordingly, there are advantages in that the maintenance and repair of the battery pack is facilitated and the general life span of the battery pack can be prolonged. 
     Further, in accordance with the exemplary embodiments of the present invention, a battery module including an inappropriate battery cell is replaced with a battery module including a new battery cell by performing battery cell grading for determining a state of charge (SOC), a state of health (SOH), etc. of each of the battery cells by measuring the capacity, internal resistance, etc. of each of the battery cells constituting the battery pack. Accordingly, there are advantages in that a process of manufacturing the battery cells can be simplified and productivity can be improved because a grading task for the battery cells performed in a process of manufacturing the battery cells can be omitted. 
     Further, in accordance with the exemplary embodiments of the present invention, the battery cells can be independently charged based on the characteristic of each battery cell. Accordingly, there are advantages in that a charging imbalance state of the battery cells can be prevented, the life span of the battery pack can be prolonged, and an available capacity of the battery pack can be maximized. 
     In the exemplary embodiments of the present invention, an active cell-balancing method is performed. Accordingly, a charging imbalance problem due to the imbalance of battery cells in a battery management apparatus adopting a conventional passive cell-balancing method is not generated. 
     Further, in the exemplary embodiments of the present invention, a cell having a high or low capacity is used without changing battery equipment according to a necessary capacity. Accordingly, there is an advantage in that a battery pack easily dealing with use environments can be supplied because the capacity of the battery pack can be simply changed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view showing a battery pack of a state in which a plurality of battery modules is coupled together in order to describe an exemplary embodiment of the present invention; 
         FIG. 2  is a perspective view showing a battery module including a battery cell in order to describe an exemplary embodiment of the present invention; 
         FIG. 3  is a schematic diagram showing the battery module according to an exemplary embodiment of the present invention; 
         FIG. 4  is a block diagram of the battery module according to an exemplary embodiment of the present invention; 
         FIG. 5  is a schematic diagram showing a connection relationship between a plurality of the battery modules and a battery management system (BMS) in order to describe an exemplary embodiment of the present invention; 
         FIG. 6  is a schematic diagram showing a program control module included in the battery management system in order to describe an exemplary embodiment of the present invention; 
         FIG. 7  is a schematic diagram showing an example of the battery management system to which an exemplary embodiment of the present invention is applied; 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Hereinafter, some exemplary embodiments of the present invention are described in detail with reference to the accompanying drawings. 
       FIG. 1  is a perspective view illustrating an exemplary embodiment of the present invention and shows a battery pack  1 . Further,  FIG. 2  is a diagram showing one of battery modules  2  constituting the battery pack  1 . 
     In a description relating to the exemplary embodiment of the present invention, it is assumed that the battery module  2  (refer to  FIG. 2 ) forms a basic unit capable of supplying a power source and a number of the battery modules  2 , coupled together at regular intervals so that they can be dismantled and assembled in a casing  3  (refer to  FIG. 1 ), form the battery pack  1 . 
     Meanwhile, the battery module  2  preferably includes a tray  5 , a battery cell  7 , a cell charger  9 , a cell controller  11 , a heating mat  13 , and a temperature sensor  15  as one set. 
     Further, in the exemplary embodiment of the present invention, the battery modules  2  preferably are configured to be easily assembled in the casing  3  using fastening members  16  (refer to  FIG. 1 ), such as screws, and to be easily replaced in the casing  3  as occasion demands. The exemplary embodiment of the present invention is described in more detail below. 
     The casing  3  includes a reception space in which the battery modules  2  can be accommodated. The casing  3  further includes an opening  3   a  having one face opened. A plurality of guide slots  3   b  is formed in the opposite sides of the casing  3  (both internal faces on the basis of the front face of  FIG. 2 ). 
     The trays  5  are inserted into the guide slots  3   b , provided in the opposite internal faces of the casing  3 , at regular intervals. The guide slots  3   b  are disposed at regular intervals in a certain direction. The trays  5  inserted into the guide slots  3   b  are stacked in a certain direction. 
     Each of the trays  5  has extension portions  5   a  on its both sides. The extension portions  5   a  are inserted into the guide slots  3   b . That is, the extension portions  5   a  are inserted into the guide slots  3   b  provided in the casing  3 . Further, the trays  5  can be robustly fastened to the casing  3  using the fastening members  16 , such as screws. 
     The trays  5  are fastened to the casing  3  using the fastening members  16 , such as screws, so that the battery module  2  can be easily detached from the casing  3  when the corresponding battery module  2  is defective or run down and a new battery module  2  can be easily coupled to the casing  3  by unfastening the fastening members  16 , such as screws. 
     Since the trays  3  and the casing  3  are coupled together by the fastening members  16  such as screws, the maintenance and repair of the battery pack  1  is facilitated, and the life span of the battery pack  1  can be prolonged. 
     The battery cells  7  are provided in the respective trays  5 . The battery cells  7  are charged with a power source and so they can supply a power source externally. The battery cell  7  is coupled to the tray  5 . The battery cell  7  includes terminals  7   a  and  7   b  connecting an electrode of a negative polarity and an electrode of a positive polarity. The terminals  7   a  and  7   b  can be used to drain a power source, charged in the battery cell  7 , externally or to charge the battery cell  7  with a power source. 
     The cell charger  9  and the cell controller  11 , as shown in  FIGS. 3 and 4 , can be coupled to a printed circuit board (PCB) or can be provided in the form of a chip. The cell charger  9  functions to charge the battery cell  7 . The cell charger  9  preferably corresponds to one battery cell  7 . 
     The cell controller  11  can control a corresponding cell charger  9 . Further, the heating mat  13  and the temperature sensor  15  are electrically connected to the cell controller  11 . 
     That is, the cell controller  11  can receive a value measured by the temperature sensor  15  and control the heating mat  13 . A connector  11   a  (refer to  FIG. 2 ) is provided in the printed circuit board (PCB) in which the cell controller  11  is provided. The cell controller  11  is electrically connected to the temperature sensor  15  through the connector  11   a.    
     The number of cell controllers  11  preferably corresponds to the number of battery modules  2 . Further, a communication connector  11   b  connected to a main controller  17  (refer to  FIGS. 5 to 7 ) (i.e., a battery management system (BMS) is provided in the printed circuit board (PCB) in which the cell controller  11  is provided. Accordingly, the cell controller  11  can send and receive data to and from the main controller  17  through the communication connector  11   b.    
     The temperature sensor  15  can measure the temperature of the battery cell  7  and send a measured value to the cell controller  11  or the main controller  17 . 
     When the temperature of the battery cell  7  is low, the heating mat  13  can be controlled by the cell controller  11  in order to raise the temperature of the battery cell  7 . The heating mat  13 , as shown in  FIGS. 1 and 2 , preferably is configured to surround the battery cell  7  or provided in one side of the battery cell  7 . 
     Meanwhile, the battery module  2  can be supplied with a power source for driving the elements of the battery module  2 . 
       FIG. 6  is a diagram illustrating an exemplary embodiment of the present invention and is a block diagram showing the main elements of the battery management system. Referring to  FIG. 6 , the battery modules  2  of the present invention are electrically connected to each other and connected to each other so that they can be controlled by the respective main controllers  17 . 
     To the main controller  17  are electrically connected a current sensor  19  for sensing current coming from the battery pack  1  and a current breaking switch  21  for breaking current coming from the battery pack  1 . 
     The current breaking switch  21  preferably includes elements suitable for power control, such as a number of insulated gate bipolar transistors (IGBT) or power FETs which are coupled in parallel and are capable of controlling high power. 
     The main controller  17 , as shown in  FIG. 6 , includes a charging control module  23  for receiving information about a state of charge (SOC) of each of the battery cells  7  from the cell controllers  11  and controlling each of the cell chargers  9  based on the information. 
     The charging control module  23  is a control program for controlling the cell chargers  9 . The charging control module  23  can receive data, such as a voltage and a charging current of the battery cell  7 , from the cell controller  11 , analyze the received data, and send a charging command to the cell charger  9  if the battery cell  7  needs to be charged. 
     The main controller  17  further includes a temperature control module  27 . The temperature control module  27  receives signals corresponding to values measured by the temperature sensors  15  and controls the heating mats  13  or the cooling fan  25  for controlling the temperature of the battery cells  7 . The cooling fan  25  is installed in the casing  3  and it can function to lower the general temperature of the battery pack  1 . 
     The temperature control module  27  is a control program for appropriately maintaining the temperature of the battery cells  7 . 
     The main controller  17  includes a battery cell protection control module  29  for controlling the current breaking switch  21  in response to an input signal from the current sensor  19 . The battery cell protection control module  29  is a control program capable of protecting the battery cells  7  from overcurrent or overcharging. 
     The main controller  17  further includes a cell grading control module  31 . The cell grading control module  31  performs a cell grading process of checking the capacities of the battery cells  7  based on signals received from the respective cell controllers  11  and determining whether the battery cells  7  are appropriate. 
     The cell grading control module  31  is a control program for performing the cell grading process for the battery cells  7 . 
     The cell grading control module  31  can determine the remaining life span of the battery cells  7  by calculating the life span of the battery cells  7  based on respective signals received from the cell controllers  11 . If the cell grading control module  31  determines that a specific battery cell  7  is inappropriate and run down, the battery module  2  including the corresponding battery cell  7  can be removed or replaced, thereby prolonging the life span of the battery pack  1 . 
     In this description, for convenience&#39; sake, the cell grading process is illustrated to determine a state of charge (SOC), a state of health (SOH), etc. of the battery cell. 
     The main controller  17  further includes a communication control module  33  for sending data, related to the battery cells  7  and received from the cell controllers  11 , and data processed in relation to the data to an external memory  39  or for communicating the data with an external computer. 
     The communication control module  33  is a control program capable of sending and receiving data to and from an external device, such as a computer device. Meanwhile, the main controller  17 , as shown in  FIG. 5 , includes communication ports  47 , such as a CAN communication port  41 , a TCP/IP communication port  43 , and a USB communication port  45 . The communication ports  47  can exchange data with the external computer device in various ways under the control of the communication control module  33 . 
     Further, internal memories  35  (refer to  FIG. 6 ) are connected to the respective cell controllers  11 . The main controller  17  further includes a history management control module  37  for recording and managing the history of each of the battery cells  7  in the respective internal memories  35 . 
     The history management control module  37  functions to manage data, such as the history of the past of each of the battery cells  7  so that the battery pack  1  can be managed in an optimal state. 
     The operation and function of the battery pack  1  configured as above according to an exemplary embodiment of the present invention is described in detail below. 
     First, a worker inserts the battery modules  2 , included in the battery cell  7 , into the guide slots  3   b  provided in the casing  3  and couples the battery modules  2  to the casing  3  using the fastening members  16 , such as screws. 
     Next, the worker inserts the extension portions  5   a , provided on both sides of each of the trays  5  constituting the battery modules  2 , into the guide slots  3   b . Next, the worker couples the trays  5  to the casing  3  using the fastening members  16 , such as screws. As described above, since the battery modules  2  are sequentially inserted into the casing  3  and fastened thereto using the fastening members  16 , the battery pack  1  of an assembly form can be completed. 
     The number of battery modules  2  connected to the battery pack  1  can be different according to a necessary capacity of power in order to appropriately control the capacity of the battery pack  1  as occasion demands. 
     Further, a control process through the main controller  17  according to an exemplary embodiment of the present invention is described below. 
     The cell controller  11  checks a voltage, a charging current, etc. of the battery cell  7 . Further, the temperature sensor  15  senses the temperature of the battery cell  7  and sends the sensed temperature to the cell controller  11 . Further, the cell controller  11  stores information about the battery cell  7  in the internal memory  35  and simultaneously sends the information to the main controller  17 . 
     Further, the current sensor  19  senses the current of the battery pack  1  and sends the sensed current to the main controller  17 . 
     The main controller  17  inputs information about the battery cell  7  to the external memory  39  through the communication control module  33 . Further, the main controller  17  can load information about the battery cell  7 , stored in the external memory  39 . 
     The main controller  17  sends a signal to a corresponding cell controller  11  if it determines that a corresponding battery cell  7  needs to be charged based on the information about the corresponding battery cell  7  and the data received from the current sensor  19 . In response to the signal, the cell controller  11  controls a corresponding cell charger  9  so that it charges the corresponding battery cell  7 . 
     The temperature control module  27  of the main controller  17  sends a control signal to the cell controller  11  when the temperature of a specific battery cell  7  has a set value or less. In response to the control signal, the cell controller  11  operates the heating mat  13  in order to raise the temperature of the specific battery cell  7 . 
     Further, when the temperature of the battery cells  7  is higher than a set value or more, the temperature control module  27  of the main controller  17  operates the cooling fan  25 . When the cooling fan  25  is operated as described above, the temperature of the battery cells  7  is generally lowered. 
     If the battery cell protection control module  29  of the main controller  17  determines that a specific battery cell  7  has been overdischarged or overcharged or the temperature of the battery cell  7  has exceeded a normal range based on the data received from a corresponding cell controller  11 , it operates the current breaking switch  21  in order to protect the battery pack  1 . 
     Meanwhile, the cell grading control module  31  of the main controller  17  can pick out an inappropriate battery module  2  by checking the capacity of a corresponding battery cell  7 , received from the cell controller  11 . Accordingly, the worker can remove the inappropriate battery module  2  from the casing  3  and install an appropriate battery module  2  in the casing  3 . Consequently, since a battery cell grading process can be performed in a process of manufacturing the battery pack  1 , the battery pack  1  with an excellent quality can be fabricated. 
     Further, the cell grading control module  31  calculates the life span of the battery cell  7  based on the data received from the cell controller  11 . Accordingly, the general life span of the battery pack  1  can be prolonged by replacing the battery module  2 , including a run-down battery cell  7 , with the battery module  2  including a new battery cell  7 . 
     The signals sent to the main controller  17  can be stored in the external memory  39  through the communication control module  33 . 
     In particular, the history management control module  37  of the main controller  17  databases the histories of the battery modules  2  and stores and manages the data. 
     In accordance with the exemplary embodiments of the present invention, a process of manufacturing the battery pack can be simplified and the manufacturing cost can be reduced because battery cell-balancing needs not to be performed through additional processes. 
       FIGS. 8 to 10  are exemplary photographs to which the exemplary embodiments of the present invention are applied. 
     
       
         
               
             
               
               
               
               
             
           
               
                   
               
               
                 &lt;Description of symbols&gt; 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                   
                   
                  1. battery pack, 
                   
               
               
                   
                   
                  2. battery module, 
                   
               
               
                   
                   
                  3. casing, 
                   
               
               
                   
                   
                  3a. opening, 
                   
               
               
                   
                   
                  3b. guide slot, 
                   
               
               
                   
                   
                  5. tray, 
                   
               
               
                   
                   
                  7a., 7b. terminal, 
                   
               
               
                   
                   
                  9. cell charger, 
                   
               
               
                   
                   
                 11. cell controller, 
                   
               
               
                   
                   
                 11a., 11b. connector, 
                   
               
               
                   
                   
                 13. heating mat, 
                   
               
               
                   
                   
                 15. temperature sensor, 
                   
               
               
                   
                   
                 17. main controller, 
                   
               
               
                   
                   
                 19. current sensor, 
                   
               
               
                   
                   
                 21. current breaking switch, 
                   
               
               
                   
                   
                 23. charging control module, 
                   
               
               
                   
                   
                 25. cooling fan, 
                   
               
               
                   
                   
                 27. temperature control module, 
                   
               
               
                   
                   
                 29. battery cell protection control module, 
                   
               
               
                   
                   
                 31. cell grading control module, 
                   
               
               
                   
                   
                 33. communication control module, 
                   
               
               
                   
                   
                 35. internal memory, 
                   
               
               
                   
                   
                 37. history management control module, 
                   
               
               
                   
                   
                 39. external memory, 
               
               
                   
                   
               
             
          
         
       
     
     While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.