Abstract:
An internal resistance testing device includes an excitation source and a battery pack, an adjustable resistance R, a sampling unit, and a control unit. The excitation source and the battery pack form a loop circuit. The adjustable resistance R may be located at the loop circuit formed by the excitation source and the battery pack. The sampling unit samples the voltage between two sides of the battery pack, the voltage between two sides of the adjustable resistance R, and the value of the adjustable resistance R. The control unit calculates internal resistance of the battery pack according to the signal value collected by the sampling unit. The internal resistances of different voltage-ranges the battery pack are determined by adjusting the value of the adjustable resistance R to cause the actual excitation voltage to be equal to the range voltage of the sampling unit. The voltage between two sides of the adjustable resistance R is made equal to the range voltage of the sampling unit by adjusting the value of the adjustable resistance R, which effectively improves measurement accuracy of the internal resistance.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority to, and the benefit of Chinese Patent Application No. 2009-10109967.2 filed Oct. 29, 2009, the entirety of which is incorporated herein by reference. 
       BACKGROUND 
       [0002]    1. Field 
         [0003]    This document relates to a device and method of testing an internal resistance of a battery pack, and more particularly, to a device and method of testing the internal resistance of a battery pack used in an electric vehicle and a hybrid powered vehicle. 
         [0004]    2. Description of Related Art 
         [0005]    The battery pack plays an important role in electric vehicle and hybrid power vehicle. The battery pack system is generally coupled in series. Individual cells in the battery pack may become damaged and affect the entire capacity of the battery pack. That means, the entire capacity of the battery pack can be determined by one or more damaged cells. Accordingly, accurately measuring each cell state is necessary to avoid the failure of the battery pack. 
         [0006]    At present, the testing method for the internal resistance of the battery pack includes a direct current discharge method and an alternating current injection method. The direct current discharge method includes generating an instant load current generated by a battery pack, measuring the instant change of voltage at the electrode pole of the battery pack, and calculating the internal resistance of the battery pack. This has several disadvantages. First, the remaining capacity must be measured and displayed frequently, which requires the frequent measuring of the internal resistance, and care must be taken so as not to influence the normal operation and reduce the remaining capacity of the battery pack. 
         [0007]    Second, the number of the battery packs in the electric vehicle is large, and such measurement may waste a large portion of the capacity of the battery pack, and may be only suitable when a large load resistance is applied and measured with a high current scope or other device. If the battery pack current is measured with a low current scope or other device, it may not be properly loaded with the required large current of about several tens of amperes in short amount of time of several seconds. Accordingly, a large current passes through the battery pack, which may damage the electrodes in the battery pack and may adversely affect measurement accuracy. Further, this method may not be used with hybrid vehicles. 
         [0008]    The alternating current injection method includes adding a constant alternating audio current source to two sides of the battery pack, detecting the voltage difference between the two sides of the battery pack, and detecting the phase difference therebetween. The internal resistance of the battery pack may be determined according to Ohms&#39; law. 
         [0009]    In the alternating current injection method, safely detecting the internal resistance of the battery pack online may be realized with no need to discharge the battery pack, which avoids affecting performance of the battery pack. However, similar to the problems associated with the direct current discharge method, the alternating current injection method has a limitation problem of the voltage scope of the detected battery pack. Moreover, the alternating current injection method needs to used a processor or master control unit (MCU) to calculate certain trigonometric functions. Thus, the hardware circuit and algorithm is complicated, which affects measurement accuracy. 
       SUMMARY 
       [0010]    The present invention is directed to solve at least one problem existing in the prior art. Accordingly, in order to solve the limitation problem of the voltage scope of the detected battery pack in the internal resistance test of the battery pack in prior art, the present invention provides a device and a method to test the internal resistance of the battery pack having different voltage scopes, which effectively improves the measurement accuracy of the internal resistance. 
         [0011]    According to an aspect of the invention, an internal resistance testing device may be provided, comprising: 
         [0012]    an excitation source and a battery pack, which may form a loop circuit; 
         [0013]    an adjustable resistance R located at the circuit formed by the excitation source and the battery pack; 
         [0014]    a sampling unit configured to collect the voltage between two sides of the battery pack, the voltage between two sides of the adjustable resistance R and the value of the adjustable resistance R; 
         [0015]    a control unit, which may calculate the internal resistance of the battery pack according to the signal value collected by the sampling unit; 
         [0016]    According to another aspect of the present invention, a testing method based on the aforementioned internal resistance testing device may be disclosed, comprising following steps: 
         [0017]    a) injecting an excitation and the sampling unit collects the excitation voltage V 2  between the two sides of the battery pack, the excitation voltage V 1  between the two sides of the adjustable resistance R and the value of the adjustable resistance R; 
         [0018]    b) adjusting the value of the adjustable resistance R to cause the actual excitation voltage to be equal to the range voltage of the sampling unit; 
         [0019]    c) calculating the internal resistance of the battery pack according to signal value collected by the sampling unit. 
         [0020]    In the aforementioned technologic scheme, by adjusting the value of the adjustable resistance R, the voltage between two sides of the adjustable resistance R collected by the sampling unit is equal to the range voltage of the sampling unit, which may test the internal resistance of the battery pack having different voltage scope. Moreover, by adjusting the adjustable resistance R, the adjustment of current and voltage in the circuit may be realized and the voltage between two sides of the adjustable resistance R collected by the sampling unit is equal to the range voltage of the sampling unit. The aforementioned technologic scheme may improve the measurement accuracy of the internal resistance of the battery pack effectively. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    These and other aspects and advantages of the invention will become apparent and more readily appreciated from the following descriptions taken in conjunction with the drawings in which: 
           [0022]      FIG. 1  shows a block diagram of the internal resistance test device of the battery pack according to an embodiment of the present invention; 
           [0023]      FIG. 2  shows a coarse adjustment flow chart of the adjustable resistance in the internal resistance test device of the battery pack in  FIG. 1 ; 
           [0024]      FIG. 3  shows a fine adjustment flowchart of the adjustable resistance in the internal resistance test device of the battery pack in  FIG. 1 ; 
           [0025]      FIG. 4  is a flowchart showing testing of the internal resistance of the battery pack in  FIG. 1 ; 
           [0026]      FIG. 5  is a flowchart showing testing of the internal resistance of the battery pack in  FIG. 1 ; 
       
    
    
     DETAILED DESCRIPTION 
       [0027]    Reference will be made in detail to embodiments of the present invention. The embodiments described herein with reference to drawings are explanatory, illustrative, and used to generally to understand the disclosure. The embodiments shall not be construed to limit the present invention. The same or similar elements and the elements having the same or similar functions are denoted by like reference numerals throughout the descriptions. 
         [0028]    As shown in  FIG. 1 , an embodiment of the present invention discloses an internal resistance testing device of the battery pack, which includes an excitation source and a battery pack, an adjustable resistance R, a sampling unit and a control unit. The excitation source and the battery pack may form a loop circuit. The adjustable resistance R may be located at the circuit formed by the excitation source and the battery pack. The sampling unit may be configured to measure the voltage between two sides of the battery pack, the voltage between two sides of the adjustable resistance R, and the value of the adjustable resistance R. And the control unit may calculate the internal resistance of the battery pack according to the signal value collected by the sampling unit. 
         [0029]    According to a preferred embodiment, the excitation source may include an alternating excitation source, which may form a loop circuit with the battery pack, a transistor or switch, and the adjustable resistance R. The excitation source may inject an alternating excitation signal via the control end of the transistor, so as to provide a sine wave excitation signal to the circuit, an excitation voltage between two sides of the adjustable resistance, and an excitation voltage V between two sides of the battery pack. 
         [0030]    The sampling unit may determine the voltage between two sides of the battery pack, the voltage between two sides of the adjustable resistance R, and the value of the adjustable resistance R. After the circuit is injected with the alternating excitation signal, excitation voltages between two sides of the adjustable resistance R and between two sides of the battery pack may be produced, and the sampling unit may determine excitation voltages between two sides of the adjustable resistance and between two sides of the battery pack, as well as the value of the adjustable resistance. Preferably, the sampling unit may include a collection chip, such as a “dual standard buck with integrated switching MOSFET,” commercially available from Intersil Corp., model CS5463, or a similar integrated device capable of measuring instantaneous current and voltage, and perform calculations thereon. 
         [0031]    The control unit may be connected with the sampling unit, and may calculate the internal resistance of the battery pack according to the signal value collected by the sampling unit to determine the internal resistance of the battery pack. Preferably, the control program corresponding to the control unit may be integrated into a sampling unit. In that regard, the control unit, along with the control program, may be incorporated into the sampling unit, such as the dual standard buck with integrated switching MOSFET. Because the function of the control unit and/or the sampling unit may be combined, the terms “collected,” “sampled,” “determined,” “measured,” and the like may be used interchangeably throughout this document. The components may be separate and distinct components or alternatively, may be functionally and/or physically combined in a signal package or board. The battery pack preferably includes at least one cell. 
         [0032]    According to another embodiment of the present invention, a testing method based on the aforementioned internal resistance testing device of the battery pack, includes: 
         [0033]    a) injecting an alternating excitation and the sampling unit collects the voltage between two sides of the battery pack, the voltage between two sides of the adjustable resistance R and the value of the adjustable resistance R; 
         [0034]    b) adjusting the value of the adjustable resistance R to cause the actual excitation voltage to be equal to the range voltage of the sampling unit; 
         [0035]    c) calculating the internal resistance of the battery pack according to the signal value collected by the sampling unit. 
         [0036]    The control process is described hereinafter: 
         [0037]    As shown in  FIG. 2  and  FIG. 3 ,  FIG. 2  shows a coarse adjustment process while  FIG. 3  shows a fine adjustment process. As shown in  FIG. 2 , the excitation source may provide an alternating excitation signal to the circuit formed by the adjustable resistance and the battery pack via the control end of the transistor. Thus, a sinusoidal excitation current may be provided to the circuit. In response, an excitation signal V 1  may be produced between two sides of the adjustable resistance R, and an excitation signal V 2  may be produced between two sides of the battery pack. 
         [0038]    The sampling unit may determine (collect or measure etc.) the following quantities: a) the excitation voltage V 1  between two sides of the adjustable resistance R, b) the excitation voltage V 2  between two sides of the battery pack, and c) the value of the adjustable resistance R. The sampling unit may send the collected signal to the control unit for further calculation and/or processing, where applicable; 
         [0039]    The value of the adjustable resistance R is coarsely adjusted to cause the excitation voltage V 2  to be about equal to a maximum range voltage V (standard) of the sampling unit, which determines if the excitation voltage signal collected by the sampling unit is clipped; 
         [0040]    The adjustable resistance R is then coarsely adjusted to increase the value of the adjustable resistance R while the sampling unit collects the voltage V 1  between the two sides of the adjustable resistance R, the voltage V 2  between the two sides of the battery pack, and the value of the adjustable resistance R. The sampling unit transmits or sends the collected signal values to the control unit. The control unit (or the sampling unit if combined into one component) may compare the voltage V 2  between two sides of the battery pack with the range voltage V (standard); 
         [0041]    If V 2 =V (standard), interpreting a clipping produced in the waves; so that, keeping coarse adjustment of the adjustable resistance R to increase the value of the adjustable resistance R, the excitation current in the circuit may be reduced, the sampling unit may continuously collect the voltage between two sides of the adjustable resistance R, the voltage between two sides of the battery pack and the value of the adjustable resistance R, as well as sending the collected signal value to the control unit. 
         [0042]    The control unit may compare the voltage V 2  between two sides of the battery pack with the maximum range voltage V (standard) of the sampling unit. At that moment, if V 2  is still equal to V (standard), clipping or distortion may still exist in the signal, so that, keeping increasing the value of the adjustable resistance R until V 2  is less than V (standard); 
         [0043]    If V 2  is less than V (standard), beginning a fine adjustment of the adjustable resistance R to cause the voltage between two sides of the battery pack collected by the sampling unit is equal to the maximum range voltage V (standard) of the sampling unit. The concrete fine adjustment process as follow: 
         [0044]    During the coarse adjustment of the adjustable resistance R, the control unit records the value of the adjustable resistance R 1  which causes V 2 =V (standard) at last time and the following value of the adjustable resistance R 2  which causes V&lt;V (standard). If to cause the excitation voltage value between two sides of the battery pack is equal to the maximum range voltage of the sampling unit, the critical value of the adjustable resistance R is R 0 , so the data range of RO is from R 1  to R 2 , and the fine adjustment of the adjustable resistance R from R 1  to R 2 ; 
         [0045]    As an optimum technology scheme, a is a minimum unit in fine adjustment of the adjustable resistance, m and n are integer variables set in system. 
         [0046]      FIG. 3  shows fine adjustment of the adjustable resistance R. During fine adjustment, adjusting the adjustable resistance R to cause the value of the adjustable resistance R is equal to an average value R 3  of R 1  and R 2 . The control unit may calculate the current in the circuit according to the formula I=V 1 /R 3  and the voltage value V 1  between two sides of the adjustable resistance R collected by the sampling unit. By collecting the voltage V 2 a between two sides of the battery pack, the sampling unit may send the voltage V 2 a between two sides of the battery pack to the control unit; 
         [0047]    The control unit may compare the voltage V 2 a between two sides of the battery pack with V (standard). If the voltage V 2 a between two sides of the battery pack is equal to V (standard), the control unit may perform fine adjustment #1 of the adjustable resistor R, as shown in  FIG. 4 . If the voltage V 2 a between two sides of the battery pack is less than V (standard), the control unit may perform fine adjustment #2 of the adjustable resistor R, as shown in  FIG. 5 . 
         [0048]    As shown in  FIG. 4 , if the voltage V 2 a between two sides of the battery pack is less than V (standard), R 3 &lt;R 0 , the adjustable resistance R is needed to increase. Adjusting the adjustable resistance R to cause the value of the adjustable resistance R is equal to an average value R 5  of R 2  and R 3 , setting R 5 =ma. The control unit may calculate the current of the circuit according to the voltage V 1  between two sides of the adjustable resistance, the value of the adjustable resistance R 5  collected by the sampling unit, and using the formula I=V 1 /R 5 , and the voltage V 2 b between two sides of the battery pack which is collected by the sampling unit and sent to the control unit. If the voltage V 2 b between two sides of the battery pack collected by the sampling unit is still equal to V (standard), R 5 &lt;R 0 , keeping increasing of the adjustable resistance R; 
         [0049]    Fine adjustment of the adjustable resistance R to cause the value of the adjustable resistance R is (m+1) (a). The sampling unit may continuously collect the voltage V 2 c between two sides of the battery pack and send which to the control unit. If at the moment the voltage V 2 c between two sides of the battery pack collected by the control unit is less than V (standard), the control unit may set the value of the adjustable resistance R is (m+1)(a), that is, to cause the voltage between two sides of the battery pack is equal to V, the value of the adjustable resistance R is adjusted to be R=(m+1) (a), the internal resistance of the battery pack measured is most accurate at that moment. 
         [0050]    If the voltage V 2 c between two sides of the battery pack received by the control unit is equal to V (standard), keep increasing the value of the adjustable resistance R, finely adjusting the adjustable resistance R to cause the value of the adjustable resistance R=(m+2) (a); then keep collecting the voltage between two sides of the battery pack. If the voltage between two sides of the battery pack is less than V (standard), the value of the adjustable resistance R is finally selected (m+2)(a), that is when the value of the adjustable resistance R is adjusted to be (m+2)(a), the internal resistance of the battery pack measured is most accurate; otherwise, keep increasing the value of the adjustable resistance via the minimum unit of the fine adjustment, with reference to the fine adjustment, until the value of the adjustable resistance R is (m+x−1) (a), thereof x is the fine times, the voltage between two sides of the battery pack is equal to V (standard). When the value of the adjustable resistance R is (m+x)(a), the voltage between two sides of the battery pack is less than V (standard); then only need to adjust the value of the adjustable resistance R to be (m+x)(a), the voltage between two sides of the battery pack is equal to V (standard), at that moment, the internal resistance of the battery pack measured is most accurate. 
         [0051]    If the voltage V 2 b between two sides of the battery pack collected by the sampling unit is less than V (standard), R 5 &gt;R 0 , need to reduce the value of the adjustable resistance R, fine adjusting the value of the adjustable resistance R=(m−1)(a), and the sampling unit may continuously collect the voltage V 2 g between two sides of the battery pack and send the voltage V 2 g to the control unit. If the voltage V 2 g of the battery pack collected by the control unit is equal to V (standard), the control unit may set the value of the adjustable resistance R is (m−1)(a), that is, if want the voltage between two sides of the battery pack is V (standard), need to adjust the value of the adjustable resistance R=(m−1)(a), at that time, the internal resistance of the battery pack is most accurate. 
         [0052]    If the voltage V 2 g of the battery pack collected by the control unit is less than V (standard), keep reducing the value of the adjustable resistance R, finely adjusting the adjustable resistance R to cause the value of the adjustable resistance R =(m−2)(a), then keep collecting the voltage between two sides of the battery pack. If the voltage between two sides of the battery pack is equal to V (standard), the adjustable resistance R is finally adjusted to (m−2)(a), that is, when the adjustable resistance R is adjusted to (m−2)(a), the internal resistance of the battery pack measured is most accurate. Otherwise, keep reducing the value of the adjustable R, with reference to the method of fine adjustment, until the value of the adjustable resistance R is (m−z−1)(a), in which z is the fine times, the voltage between two sides of the battery pack is equal to V (standard). When the value of the adjustable resistance R is (m−z)(a), the voltage between two sides of the battery pack is less than V (standard), so only when the value of the adjustable resistance R is adjusted to be (m−z−1)(a), the voltage between two sides of the battery pack is equal to V (standard), at that moment, the internal resistance of the battery pack measured is most accurate. 
         [0053]    As shown in  FIG. 5 , fine adjustment #2 of the adjustable resistor is shown because when the voltage V 2 a between two sides of the battery pack is less than V (standard), R 3 &gt;R 0  and the value of the adjustable resistance R is needed to reduce. Adjusting the adjustable resistance R to cause the value of the adjustable resistance R is equal to the average value R 4  of R 1  and R 3 , setting R 4 =n(a). The control unit may calculate the current in the circuit according to the voltage V 1  between two sides of the adjustable resistance and the value of the adjustable resistance R 4  collected by the sampling unit and the formula I=V 1 /R 4 . The sampling unit may collect the voltage V 2 d between two sides of the battery pack and send the voltage V 2 d to the control unit. If V 2 d is still less than V (standard), R 3 &gt;R 0 , keep reducing the value of the adjustable resistance R; 
         [0054]    By fine adjustment of the adjustable resistance, the value of the adjustable resistance is (n−1)(a). The sampling unit may continuously collect the voltage V 2 f between two sides of the battery pack and send the voltage V 2 f to the control unit. If at that moment the voltage V 2 f between two sides of the battery pack collected by the control unit is about equal to V (standard), the value of the adjustable resistance R is finally selected (n−1) a by the control unit, that is, to cause the voltage between two sides of the battery pack is equal to V (standard), the value of the adjustable resistance R is adjusted R=(n−1)(a), at that moment, the internal resistance of the battery pack measured is most accurate. If the voltage V 2 f between two sides of the battery pack received by the control unit is less than V (standard), keep reducing the value of the adjustable resistance R and by finely adjusting the adjustable resistance R, the value of the adjustable resistance R=(n−2)(a). Then keep collecting the voltage between two sides of the battery pack, if the voltage between two sides of the battery pack is about equal to V (standard), the value of the adjustable resistance R is finally adjusted to (n−2)(a), that is when the value of the adjustable resistance R is (n−2)(a), the internal resistance of the battery pack measured is most accurate. Otherwise, keep reducing the value of the adjustable resistance R with the minimum unit of the fine adjustment, with reference to the method of fine adjustment, until when the value of the adjustable resistance R is (n−y−1)(a), in which (y) is the times of fine adjustment, the voltage between two sides of the battery pack is equal to V (standard). When the value of the adjustable resistance R is (n−y)(a), the voltage between two sides of the battery pack is less than V (standard), so that, only when the value of the adjustable resistance R is adjusted to be (n−y−1)(a), the voltage between two sides of the battery pack is equal to V (standard), the internal resistance of the battery pack measured is most accurate. 
         [0055]    If the voltage V 2 d between two sides of the battery pack collected by the sampling unit is about equal to V (standard), R 3 &lt;R 0  and it is needed to increase the value of the adjustable resistance R. Fine adjusting the adjustable resistance R to cause the value of the adjustable resistance R to be (n+1)(a), the sampling unit keeps collecting the voltage V 2 e between two sides of the battery pack and sending the voltage V 2 e to the control unit. If the voltage V 2 e between two sides of the battery pack received by the control unit is less than V (standard), the value of the adjustable resistance R is adjusted to be (n+1)(a) by the control unit, that is, to cause the voltage between two sides of the battery pack is V (standard), the value of the adjustable resistance R is adjusted to be (n+1)(a), and at that moment, the internal resistance of the battery pack measured is most accurate. If the voltage V 2 f between two sides of the battery pack received by the control unit is about equal to V (standard), keep increasing the value of the adjustable resistance R and by fine adjusting the adjustable resistance R, the value of the adjustable resistance R=(n+2)(a); then keep collecting the voltage between two sides of the battery pack, if the voltage V 2 f between two sides of the battery pack is less than V (standard), the value of the adjustable resistance R is finally adjusted to (n+2)(a), that is when the value of the adjustable resistance R is adjusted to be (n+2)(a), the internal resistance of the battery pack measured is most accurate. Otherwise, keep increasing the value of the adjustable resistance R with the minimum unit of the fine adjustment, with reference to the method of fine adjustment, until when the value of the adjustable resistance R=(n+w−1)(a), thereof w is the times of fine adjustment, the voltage between two sides of the battery pack is equal to V (standard) and when the value of the adjustable resistance R is (n+w)(a), the voltage between two sides of the battery pack is less than V (standard), so that, only when the value of the adjustable resistance R is adjusted to be (n+w)a, the voltage between two sides of the battery pack is equal to V (standard) and the internal resistance of the battery pack measured is most accurate. 
         [0056]    By the coarse and fine adjustment of the adjustable resistance R, the control unit may calculate the current in the circuit according to the voltage V 1  between two sides of the adjustable resistance R and the formula I=V 1 /R. Then the control unit may calculate the internal resistance making use of the voltage V 2  between two sides of the battery pack that is collected by the sampling unit and the current I in the circuit. During injecting the alternating excitation, there is a phase-difference between the excitation voltage and the excitation current, that is the power coefficient PF, so that, the internal resistance of the battery pack is r=PF*V 2 /I, and the power coefficient PF may be calculated by the control unit In the aforementioned technology scheme, the value of the adjustable resistance may be adjusted via the manual adjustment or under program control. 
         [0057]    Although explanatory embodiments have been shown and described, it would be appreciated by those skilled in the art that changes, alternatives, and modifications can be made in the embodiments without departing from spirit and principles of the invention. Such changes, alternatives, and modifications all fall into the scope of the claims and their equivalents.