Rechargeable battery controller and method for controlling output of rechargeable battery

A rechargeable battery controller for controlling output of a rechargeable battery mounted on a vehicle having a power source including an internal combustion engine, a starter motor for starting the internal combustion engine, and a vehicle controller. The rechargeable battery controller includes a control circuit for setting an upper limit for discharge power output by the rechargeable battery in a set period of time and providing the upper limit to the vehicle controller. The control circuit is programmed to reset the upper limit to a value greater than or equal to a power value required to drive the starter motor when a first requirement in which power supply from the rechargeable battery to the starter motor is scheduled and a second requirement in which the upper limit is less than the power value required to drive the starter motor are both satisfied.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2005-287793, filed on Sep. 30, 2005, the entire contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to a vehicle rechargeable battery controller and a method for controlling output of a vehicle rechargeable battery.

In recent years, a hybrid electric vehicle (HEV) having an engine and a drive motor as its power sources has been commercialized. A rechargeable battery is mounted on the HEV and supplies power to the drive motor.

When the engine outputs more power than necessary to drive the vehicle, the HEV drives a power generator with the excessive power and charges the rechargeable battery. When the vehicle is braking or decelerating, the HEV drives a motor with the rotating wheels to charge the rechargeable battery with the motor. In this case, the motor is used as a power generator. When the engine outputs insufficient power, the HEV compensates for the lack of power by discharging the rechargeable battery and driving the motor. In this case, the motor is used as a power source for the HEV.

The HEV accumulates energy in the rechargeable battery. Conventional automobiles discharge such energy into the atmosphere as heat. Thus, the energy efficiency of the HEV is higher than the energy efficiency of conventional automobiles. Further, the HEV drastically improves fuel efficiency as compared with conventional automobiles.

In an HEV, the rechargeable battery for supplying power to the drive motor is also used to supply power to a starter motor for starting the engine. However, the discharge voltage of the rechargeable battery greatly decreases at low temperatures of 0° C. or less. At such low temperatures the rechargeable battery may not be able to start the engine. To solve this problem, Japanese Laid-Open Patent Publication No. 2002-195138 describes a rechargeable battery controller (battery ECU) that limits the discharge power of the rechargeable battery to ensure starting of the engine at low temperatures.

More specifically, the battery ECU sets a minimum voltage at which driving of the starter motor with the rechargeable battery is enabled. The discharge voltage of the rechargeable battery is greater than or equal to the minimum voltage when the starter motor is driven. When the discharge voltage of the rechargeable battery decreases to the minimum voltage after the starter motor is driven, the battery ECU controls the rechargeable battery to temporarily stop the supply of power to the starter motor. The battery ECU waits until discharge current generates heat in the battery and accordingly increases the discharge voltage. The battery ECU then permits the rechargeable battery to resume power supply to the starter motor. The battery ECU continues to execute this control until the engine is started. In this manner, the battery ECU of the prior art controls the rechargeable battery to repeatedly start and stop discharging to ensure that the engine can be started under low temperatures.

SUMMARY OF THE INVENTION

A rechargeable battery mounted on an HEV is usually formed by a plurality of series-connected battery cells (cells). The battery cells may have variations in their capacities. As a result, the battery cells may have different discharge capabilities. In such a case, battery cells having a small capacity may become overdischarged and cause pole changing. When the rechargeable battery repeatedly starts and stops discharging within a short period of time, the poles of such battery cells are more likely to be changed. With the technique described in Japanese Laid-Open Patent Publication No. 2002-195138 for repeatedly turning on and off the starter motor, such pole changes are likely to occur more frequently. This would consequently shorten the life of the rechargeable battery.

It is an object of the present invention to provide a rechargeable battery controller and a method for controlling output of a rechargeable battery to ensure that an engine is started under low temperatures.

One aspect of the present invention is a rechargeable battery controller for controlling output of a rechargeable battery mounted on a vehicle having a power source including an internal combustion engine, a starter motor for starting the internal combustion engine, and a vehicle controller. The rechargeable battery control includes a control circuit connectable in communication with the vehicle controller, in which the control circuit sets an upper limit for discharge power output by the rechargeable battery in a set period of time and communicates the upper limit to the vehicle controller. The control circuit resets the upper limit to a value greater than or equal to a power value required to drive the starter motor when a first requirement in which power supply from the rechargeable battery to the starter motor is scheduled and a second requirement in which the upper limit is less than the power value required to drive the starter motor are both satisfied.

A further aspect of the present invention is a method for controlling output of a rechargeable battery mounted on a vehicle having a power source including an internal combustion engine, a starter motor for starting the internal combustion engine, and a vehicle controller. The method includes the steps of (a) setting an upper limit for discharge power output by the rechargeable battery in a set period of time and providing the upper limit to the vehicle controller, (b) determining whether or not power supply from the rechargeable battery to the starter motor is scheduled, (c) determining whether or not the set upper limit is less than a power value required to drive the starter motor, (d) resetting the upper limit set in the step of setting to a value greater than or equal to the power value required to drive the starter motor when it is determined that power supply to the starter motor is scheduled and determined that the set upper limit is less that the power value required to drive the starter motor, and (e) providing the vehicle controller with the upper limit set in the step of setting or the upper limit reset in the step of resetting.

Another aspect of the present invention is a computer program product including computer readable media encoded with program code for controlling output of a rechargeable battery mounted on a vehicle having a driving power source including an internal combustion engine, a starter motor for starting the internal combustion engine, and a vehicle controller. The program code when executed by a computer performing steps includes (a) setting an upper limit for discharge power output by the rechargeable battery in a set period of time and providing the upper limit to the vehicle controller, (b) determining whether or not power supply from the rechargeable battery to the starter motor is scheduled, (c) determining whether or not the set upper limit is less than a power value required to drive the starter motor, (d) resetting the upper limit set in the step of setting to a value greater than or equal to the power value required to drive the starter motor when it is determined that power supply to the starter motor is scheduled and determined that the set upper limit is less that the power value required to drive the starter motor, and (e) providing the vehicle controller with the upper limit set in the step of setting or the upper limit reset in the step of resetting.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A rechargeable battery controller and a method for controlling output of a rechargeable battery according to a first embodiment of the present invention will now be described with reference toFIGS. 1 to 4.

FIG. 1shows an electric vehicle on which a rechargeable battery according to a first embodiment of the present invention is mounted. One example of the electric vehicle is a hybrid electric vehicle (HEV). The electric vehicle includes an internal combustion engine24and a motor26. The internal combustion engine24and the motor26are power sources for generating power for driving a drive shaft28. The drive shaft28is connected to wheels (not shown). A rechargeable battery40, or a secondary battery, functions as a power supply source for the motor26.

The rechargeable battery40supplies power to the motor26via a relay unit29and an inverter22. The rechargeable battery40supplies power to a starter motor38for starting the engine via the relay unit29and the inverter22. The inverter22converts direct current supplied from the rechargeable battery40to alternating current for driving the motor. Wiring connecting the inverter22and a starter motor38is not shown inFIG. 1.

The engine24transmits power to the wheels via a power dividing mechanism25, reduction gears27, and the drive shaft28. The motor26transmits power to the wheels via the reduction gears27and the drive shaft28. When the rechargeable battery40is required to be charged, some of the power produced by the engine24is transmitted to a power generator23via the power dividing mechanism25.

The power generated by the power generator23is supplied to the rechargeable battery40via the inverter22and the relay unit29and is used to charge the rechargeable battery40. When the electric vehicle is decelerating or braking, the motor26is used as a power generator. The power generated by the motor26is also supplied to the rechargeable battery40via the inverter22and the relay unit29and is used to charge the rechargeable battery40.

The relay unit29includes relays30to32and a resistor33. The relay31is connected between a positive terminal of the rechargeable battery40and a high-potential input terminal of the inverter22. The relay32is connected between a negative terminal of the rechargeable battery40and a low-potential input terminal of the inverter22. The relay30is connected in series to the resistor33and is connected in parallel to the relay31. The relay30and the resistor33are used to precharge a smoothing capacitor (not shown) of the inverter22when the vehicle is activated.

The electric vehicle includes controllers, or more specifically, a rechargeable battery controller (battery ECU)1, a vehicle controller (vehicle ECU)20, and an engine controller (engine ECU)21. The engine ECU21mainly controls ignition timing and the fuel ejection amount of the engine24. The battery ECU1mainly measures the terminal voltage of the rechargeable battery40, determines the state of charge (SOC) of the rechargeable battery40, and determines whether the rechargeable battery40has deteriorated, and transmits these results as battery information to the vehicle ECU20. The structure and function of the battery ECU1will later be described in detail with reference toFIG. 2.

The vehicle ECU20controls the inverter22based on the information provided from the battery ECU1, the engine ECU21, and the like to consequently control the driving of the motor26and the starter motor38. The information provided from the engine ECU21includes the driving status of the engine24and the rotation angle of the crankshaft of the engine24. The information provided from the battery ECU1not only includes the battery information including the SOC of the rechargeable battery40but also includes the upper limit of the discharge power generated by the rechargeable battery40. Information on the depression amount of an accelerator pedal37, the depression amount of a brake pedal36, and the gearshift range selected by a gearshift lever35is input into the vehicle ECU20and used to control the inverter22.

The vehicle ECU20supplies an activation voltage (minimum operating voltage) to the relays30to32when closing the relays30to32and stops supplying the activation voltage to the relays30to32when opening the relays30to32. More specifically, the vehicle ECU20closes the relays30and32when detecting that an ignition (IG)34has been turned on. This precharges the smoothing capacitor of the inverter22. When the precharging is completed, the vehicle ECU20closes the relay31and supplies power from the rechargeable battery40to the motor26via the inverter22. The vehicle ECU20stops supplying the activation voltage when detecting that the ignition34has been turned off.

When detecting that the ignition34has been turned on, the vehicle ECU20transmits an ON-detection signal to the battery ECU1before supplying the activation voltage. When detecting that the ignition34has been turned off, the vehicle ECU20stops supplying the activation voltage and transmits an activation voltage suspension signal to the battery ECU1.

Although not shown in the drawings, a relay for switching the on and off states of the starter motor38is arranged on the wiring connecting the starter motor38and the inverter22. The vehicle ECU20closes this relay when detecting that the ignition34is located at an engine start position by supplying the relay with the activation voltage for switching the on and off states of the starter motor38. When the relay is closed, power is supplied to the starter motor38. In this case, the driving power of the starter motor38starts the engine. The vehicle ECU20provides the battery ECU1with an engine start signal when detecting that the ignition34is at the engine start position.

In the first embodiment, the rechargeable battery40is formed by connecting battery blocks B1to B20in series. The battery blocks B1to B20are accommodated in a battery case42. Each of the battery blocks B1to B20is formed by electrically connecting two battery modules in series. Each battery module is formed by electrically connecting six cells11in series. Nickel-metal hydride batteries or lithium ion batteries may be used as the cells11. The quantities of the battery blocks, the battery modules, and the cells11are not limited to the above-described structure. The structure of the rechargeable battery40is also not limited to the above-described structure.

A plurality of temperature sensors43are arranged in the battery case42. The plurality of temperature sensors43are arranged in a manner that a temperature sensor43is provided for each battery block group including battery blocks having temperatures that are relatively the same or for each battery groups including one battery block when the battery blocks have different temperatures. The grouping of the battery blocks is based on temperatures measured in advance through experiments or the like.

The structure of the rechargeable battery controller according to the first embodiment will now be described with reference toFIG. 2. As shown inFIG. 2, the battery ECU1mainly includes a current measurement unit2, a voltage measurement unit4, a temperature measurement unit3, a control circuit5, and a storage unit (memory)6.

The voltage measurement unit4measures the terminal voltage of the rechargeable battery40. In the first embodiment, the voltage measurement unit4measures terminal voltages Vu1to Vu20of the battery blocks B1to B20. The voltage measurement unit4generates voltage data specifying the terminal voltages Vu1to Vu20and provides the voltage data to the control circuit5. The voltage data is supplied to the control circuit5by the voltage measurement unit4at a preset frequency. The control circuit5stores the voltage data in the storage unit6.

The current measurement unit2measures a current value I of current of the rechargeable battery40when the rechargeable battery40is being charged or discharged. In the first embodiment, the current measurement unit2converts an analog signal provided from a current sensor44to a digital signal. Based on the digital signal, the current measurement unit2generates current data specifying the current value I of the current input to the rechargeable battery40when the rechargeable battery40is charged or current data specifying the current value I of the current supplied from the rechargeable battery40when the rechargeable battery40is discharged. The current measurement unit2outputs the generated current data to the control circuit5. The current measurement unit2generates current data indicating a negative value when the rechargeable battery40is charged and generates current data indicating a positive value when the rechargeable battery40is discharged. The current data is also provided to the control circuit5by the current measurement unit2at a preset frequency. The control circuit5also stores the current data into the storage unit6.

The temperature measurement unit3measures the battery temperature of the rechargeable battery40. In the first embodiment, the temperature measurement unit3converts an analog signal provided from the temperature sensor43of each battery block group to a digital signal. Based on the digital signal, the temperature measurement unit3generates temperature data specifying the battery temperature for each battery block group and provides the temperature data to the control circuit5. The temperature data is also provided at a preset frequency from the temperature measurement unit3to the control circuit5. The control circuit5stores the temperature data in the storage unit6.

The control circuit5includes a upper-limit setting unit7, a calculation unit8, a communication unit9, and a monitoring unit10. The upper-limit setting unit7sets an upper limit of the discharge power that can be output by the rechargeable battery40within a set period of time. In the first embodiment, the upper-limit setting unit7sets two upper limits, that is, a short-term output upper limit Pp and a long-term output upper limit Pn. The short-term output upper limit Pp and the long-term output upper limit Pn set by the upper-limit setting unit7are stored in the storage unit6as short-term output information and long-term output information, respectively.

The short-term output upper limit Pp represents an upper-limit of the discharge power that can be output by the rechargeable battery40within a short set period of time, such as one or two seconds. The short-term output upper limit Pp is used to limit the discharge output of the rechargeable battery40when the rechargeable battery40is required to be discharged to generate a high output in a short period of time, such as when the vehicle starts driving, a gearshift change is made, or the engine is started. The long-term output upper limit Pn represents an upper-limit of the discharge power that can be output by the rechargeable battery40for a period of time, such as about ten seconds. The long-term output upper limit Pn is used to limit the discharge output of the rechargeable battery40when, for example, the vehicle is normally driven.

In the first embodiment, the upper-limit setting unit7sets the short-term output upper limit Pp and the long-term output upper limit Pn using two-dimensional maps, the parameters of which are the battery temperature and the SOC. More specifically, in each two-dimensional map, the vertical axis (or horizontal axis) represents the battery temperature and the horizontal axis (or vertical axis) represents the SOC, and the optimum upper limits for the battery temperature and the SOC are indicated at intersections in the vertical axis and the horizontal axis. Such two-dimensional maps for the short-term output upper limit Pp and the long-term output upper limit Pn are generated in advance based on experiments and are stored in the storage unit6. The upper-limit setting unit7locates the lowest battery temperature in the battery temperatures of the battery block groups based on the temperature data. Then, the upper-limit setting unit7sets the optimum short-term output upper limit Pp and optimum long-term output upper limit Pn based on the lowest battery temperature, the SOC estimated by the calculation unit8, and the two-dimensional maps.

When the terminal voltage of the rechargeable battery40decreases after the vehicle starts to operate (after the engine is started), the upper-limit setting unit7lowers the upper limits to suppress the decrease in the terminal voltage of the rechargeable battery40. This control will be described with reference toFIG. 3.FIG. 3shows changes in the terminal voltage of the rechargeable battery and the upper limits set for the rechargeable battery when an upper limit lowering process is performed.

As shown inFIG. 3, when setting the short-term output upper limit Pp and the long-term output upper limit Pn, the upper-limit setting unit7sets a first reference voltage, or a relatively low reference voltage V21, for the short-term output upper limit Pp and sets a second reference voltage, or a relatively high reference voltage V22, for the long-term output upper limit Pn. The upper-limit setting unit7locates the minimum terminal voltage Vu_min from the terminal voltages Vu1to Vu20measured for the battery blocks. Then, the upper-limit setting unit7compares the minimum terminal voltage Vu_min with the first reference voltage V21and with the second reference voltage V22. This comparison is performed constantly or in fixed intervals.

When the comparison shows that the minimum terminal voltage Vu_min has decreased to the second reference voltage V22, the upper-limit setting unit7resets the long-term output upper limit Pn to a value smaller than the present value of the long-term output upper limit Pn. When lowering the long-term output upper limit Pn, the upper-limit setting unit7also rewrites the long-term output information.

When the comparison shows that the minimum terminal voltage Vu_min has decreased to the first reference voltage V21, the upper-limit setting unit7resets the short-term output upper limit Pp to a value smaller than the present value of the short-term output upper limit Pp. When lowering the short-term output upper limit Pp, the upper-limit setting unit7also rewrites the short-term output information.

The storage unit6stores a map showing the relationship between each temperature and the optimum first reference voltage V21and the optimum second reference voltage V22. The upper-limit setting unit7locates the lowest battery temperature and sets the first reference voltage V21and the second reference voltage V22using the map and the lowest battery temperature. The map may be generated to reflect the performance of the rechargeable battery40or the load on the rechargeable battery40based on the results of discharging experiments conducted in advance.

In this manner, the upper-limit setting unit7lowers the short-term output upper limit Pp and the long-term output upper limit Pn when the terminal voltage of the rechargeable battery40decreases. This suppresses the decrease in the terminal voltage of the rechargeable battery40. However, as shown inFIG. 3, the upper-limit setting unit7further lowers the short-term output upper limit Pp and the long-term output upper limit Pn when the terminal voltage of the rechargeable battery40does not increase. Although not shown inFIG. 3, the upper-limit setting unit7raises the short-term output upper limit Pp and the long-term output upper limit Pn when the minimum terminal voltage Vu_min increases sufficiently.

To further ensure that the engine is started at low temperatures, the upper-limit setting unit7resets (raises) the set upper limits if the first and second requirements described below are satisfied when starting the engine. In the first embodiment, the short-term output upper limit Pp is reset. This control will be described with reference toFIG. 4.FIG. 4shows changes in the terminal voltage of the rechargeable battery and the upper limits set for the rechargeable battery when the engine is started.

The first requirement is that power supply from the rechargeable battery40to the starter motor38(refer toFIG. 1) is scheduled. In the first embodiment, the upper-limit setting unit7determines that the first requirement is satisfied when receiving an engine start signal from the vehicle ECU20. In this case, the upper-limit setting unit7sets an engine start flag ON (FLG=1). In the first embodiment, the logic level of the engine start signal being switched from a low level to a high level as shown inFIG. 4indicates that the engine start signal has been output.

The second requirement is that the set upper limit is less than a power value α, which is required to drive the starter motor38(refer toFIG. 4). In such a state, due to the limited output, the engine is difficult to start. In the first embodiment, when comparing the short-term output upper limit Pp and the power value α, the upper-limit setting unit7determines that the second requirement is satisfied when the short-term output upper limit Pp is less than the power value α. The power value α is obtained in advance through experiments and stored in the storage unit6.

When the first and second requirements are satisfied, the upper-limit setting unit7resets the short-term output upper limit Pp and raises the short-term output upper limit Pp to a value greater than or equal to the power value α, which is required to drive the starter motor as shown inFIG. 4. In this case, the upper-limit setting unit7rewrites the short-term output information. In the example shown inFIG. 4, the upper-limit setting unit7sets the short-term output upper limit Pp to be equal to the power value α. This further ensures that the engine is started even under low temperatures.

The communication unit9outputs the short-term output upper limit Pp and the long-term output upper limit Pn to the vehicle ECU20that is mounted on the vehicle. In the first embodiment, the communication unit9provides the short-term output information and the long-term output information that is stored in the storage unit to the vehicle ECU20. The short-term output information and the long-term output information are provided to the vehicle ECU20at a preset frequency or whenever the upper limits are lowered or raised.

When the short-term output information and the long-term output information are provided, the vehicle ECU20is constrained by the short-term output upper limit Pp and the long-term output upper limit Pn when using the rechargeable battery40. More specifically, the vehicle ECU20drives the motor26(refer toFIG. 1) and the starter motor38(refer toFIG. 1) with the rechargeable battery40within the range of the short-term output upper limit Pp specified by the short-term output information or within the range of the long-term output upper limit Pn specified by the long-term output information.

The monitoring unit10monitors power supply from the rechargeable battery40to the starter motor38(refer toFIG. 1) to prevent deterioration of the rechargeable battery40caused by excessive power supply to the starter motor38. More specifically, the monitoring unit10monitors at least one of the number of times power supply from the rechargeable battery40to the starter motor38occurs (power supply occurrences), the time for each power supply (power supply time), and the time elapsed from when the starter motor38is first supplied with power (elapsed time).

In the first embodiment, the monitoring unit10monitors each of the power supply occurrences, the power supply time for each power supply occurrence, and the elapsed time. The monitoring unit10includes a timer for measuring the power supply time. An upper limit is preset for each of the power supply occurrences, the power supply time for each power supply occurrence, and the elapsed time. The set upper limits are stored in the storage unit6. The monitoring unit10compares the measured power supply occurrences, the measured power supply time for each power supply occurrence, and the measured elapsed time with the corresponding upper limits. When any of the measured values exceeds the corresponding upper limit, the monitoring unit10stops supplying power to the starter motor38.

The calculation unit8estimates the SOC of the rechargeable battery40. The estimated SOC is provided by the communication unit9to the vehicle ECU20. In the first embodiment, the calculation unit8estimates a first SOC based on an accumulated capacitance Q of the rechargeable battery40. The calculation unit8also estimates a second SOC based on a charging and discharging history of the rechargeable battery40. The calculation unit8calculates the difference between the first SOC and the second SOC, corrects the first SOC based on the calculated difference, and sets the corrected first SOC as the SOC of the rechargeable battery40.

More specifically, the first SOC is estimated in the following procedure. First, the calculation unit8reads current data stored in the storage unit6and obtains the current value I. When the obtained current value I is a value indicating a charging current (−), the calculation unit8multiplies the current value I by the charging efficiency. Next, the calculation unit8accumulates the obtained current value I (product in the case of charging) for a set period of time to calculate the accumulated capacitance Q. The calculation unit8further calculates the difference between the accumulated capacitance Q and the capacity of the rechargeable battery40that is in a fully charged state, which is calculated in advance based on experiments. The calculation unit8then calculates the ratio of the accumulated capacitance Q to the capacity of the rechargeable battery40in the fully charged state. The calculation unit8uses the calculated ratio (%) as the estimated first SOC.

The second SOC is estimated in the following procedure. First, for each battery block, the calculation unit8obtains sets of the voltage value of the terminal voltage and the current value I of the charging and discharging current based on the voltage data provided from the voltage measurement unit4and the current data provided from the current measurement unit2within a predetermined time period whenever charging and discharging occurs. The obtained sets of voltage and current data are stored in the storage unit6as the charging and discharging history.

Next, from the sets of voltage and current data for each battery block stored in the storage unit6, the calculation unit8selects a voltage and current data of a representative battery block. Sets of voltage and current data including the highest or lowest value are excluded, and a set of voltage and current data having average values is selected. The calculation unit8further calculates a linear approximation line (V-I linear approximation line) from the selected representative set of data using a regression analysis method. The calculation unit8further obtains the V intercept of the V-I linear regression line, and sets the V intercept as a no-load voltage OCV of the representative battery block.

Next, the calculation unit8estimates a polarization voltage of the rechargeable battery40based on a change amount ΔQ per unit time of the accumulated capacitance Q. More specifically, the calculation unit8performs a time delay process and an averaging process on the change amount ΔQ to eliminate change components corresponding to unnecessary high-frequency components and yield a change amount ΔQ′. Further, the calculation unit8specifies the polarization voltage referring to the calculated change amount ΔQ′ and the lowest battery temperature. The calculation unit8also refers to a two-dimensional map of which vertical axis (or horizontal axis) represents the temperature and horizontal axis (or vertical axis) represents the change amount ΔQ′. The two-dimensional map shows polarization voltages at intersections in the vertical axis and the horizontal axis. The calculation unit8estimates the specified polarization voltage as the polarization voltage of the rechargeable battery40. The two-dimensional map is also stored in the storage unit6.

Next, the calculation unit8subtracts the estimated polarization voltage from the no-load voltage OCV of the representative battery block and calculates the electromotive force of the representative battery block. Further, the calculation unit8specifies the SOC by referring to the calculated electromotive force and the lowest battery temperature and a two-dimensional map of which vertical axis (or horizontal axis) represents the temperature and horizontal axis (or vertical axis) represents the electromotive force. The two-dimensional map shows SOCs at intersections in the vertical axis and the horizontal axis. The specified SOC is estimated to be the second SOC. This two-dimensional map is also stored in the storage unit6.

In the above example, the representative battery block is selected to calculate the OCV. However, the present invention is not limited in such a manner. For example, the no-load voltage of the entire rechargeable battery may be calculated, and the electromotive force of the entire rechargeable battery may be calculated from the no-load voltage to estimate the second SOC.

A method for controlling output of the rechargeable battery according to the first embodiment of the present invention will now be described with reference toFIG. 5. The method for controlling the output of the rechargeable battery in the first embodiment is used by the battery ECU1.

As shown inFIG. 5, the upper-limit setting unit7first sets the short-term output upper limit Pp and the long-term output upper limit Pn based on the lowest battery temperature of the rechargeable battery40and the SOC estimated by the calculation unit8(step S1). Next, the upper-limit setting unit7determines whether the vehicle ECU20is outputting the engine start signal (step S2). When the engine start signal is being output, the upper-limit setting unit7sets the engine start flag ON (FLG=1) and proceeds to step S3and the subsequent steps.

In step S3, the upper-limit setting unit7determines whether the short-term output upper limit Pp is less than the power value α. When the short-term output upper limit Pp is greater than or equal to the power value α required to drive the starter motor38, the short-term output upper limit Pp does not have to be reset. In this case, the communication unit9outputs the short-term output upper limit Pp set in step S1and the long-term output upper limit Pn set in step S1to the vehicle ECU20as the short-term output information and the long-term output information (step S8).

When the short-term output upper limit Pp is less than the power value α, the upper-limit setting unit7resets the short-term output upper limit Pp, and raises the short-term output upper limit Pp to the power value α required to drive the starter motor38(step S4). When doing so, the upper-limit setting unit7rewrites the short-term output information.

Next, the communication unit9provides the short-term output upper limit Pp reset in step S4and the long-term output upper limit Pn set in step S1to the vehicle ECU20as the short-term output information and the long-term output information (step S5).

When step S5is performed, power is supplied to the starter motor38. However, the short-term output upper limit Pp set in step S1is determined as being less than the power value α in step S3. Thus, the rechargeable battery40is in a low temperature environment and may easily deteriorate. In this case, the monitoring unit10monitors the power supply from the rechargeable battery40to the starter motor38(step S6). The processing in step S7will be described in detail later.

Afterwards, the monitoring unit10determines whether a start completion signal indicating that the engine24is completely started has been received from the vehicle ECU20(step S7). When the start completion signal has not been received, the processing in step S7is performed again. When the start completion signal has been received, the monitoring unit10terminates the output control process.

When the engine start signal is not being output (FLG=0) in step S2, the engine24has been already started and the vehicle has been activated. In this case, the upper-limit setting unit7performs step S11and the subsequent steps.

In step S11, the upper-limit setting unit7determines whether the minimum terminal voltage Vu_min is less than or equal to the second reference voltage V22. When the minimum terminal voltage Vu_min exceeds the second reference voltage V22, the upper-limit setting unit7performs step S13. When the minimum terminal voltage Vu_min is less than or equal to the second reference voltage V22, the upper-limit setting unit7lowers the long-term output upper limit Pn to suppress decrease in the terminal voltage (step S12) and then performs step S13.

In step S13, the upper-limit setting unit7determines whether the minimum terminal voltage Vu_min is less than or equal to the first reference voltage V21. When the minimum terminal voltage Vu_min exceeds the first reference voltage V21, the upper-limit setting unit7performs step S15. When the minimum terminal voltage Vu_min is less than or equal to the first reference voltage V21, the upper-limit setting unit7lowers the short-term output upper limit Pp (step S14) and then performs step S15.

In step S15, the communication unit9provides the short-term output information and the long-term output information to the vehicle ECU20. This ends the processing.

In the first embodiment, when starting the engine24, the starting of the engine24is enabled only when predetermined requirements are satisfied. When the terminal voltage of the rechargeable battery40decreases after the vehicle is activated (after the engine24is started), the short-term output upper limit Pp and the long-term output upper limit Pn are lowered to suppress decrease in the terminal voltage of the rechargeable battery40. The control circuit5is programmed to perform the output control process shown inFIG. 5at a constant frequency (e.g., every 100 ms).

Step S7, which is shown inFIG. 5, will now be described in detail with reference toFIG. 6.FIG. 6is a flowchart showing a process performed when the power supply to the starter motor is monitored. The power supply monitoring process ofFIG. 6is performed by the monitoring unit10shown inFIG. 2.FIGS. 1 and 2will also be referred to in the following description of the power supply monitoring process. In the example ofFIG. 6, the power supply occurrences has a set upper limit of two, the power supply time for each power supply occurrence has a set upper limit of two seconds, and the elapsed time has a set upper limit of ten minutes. However, these upper limits are not limited to the values of the example shown inFIG. 6.

As shown inFIG. 6, when step S6, which is shown inFIG. 5, is completed, the monitoring unit10sets a total time T to zero and starts the timer (step S21). In this state, the engine start flag is set, that is, FLG=1 is satisfied. A flag FLGb is used in the loop process of step S22and the subsequent steps to indicate whether the engine start flag has been set in a previous loop. In step S21, the flag FLGb is zero.

The monitoring unit10determines whether the engine start flag has been set, that is, whether FLG>0 (step S22) is satisfied. When the engine start flag has not been set, that is, when FLG≦0 is satisfied, the flag FLGb is set to zero (step S28) and step S27is performed.

When the engine start flag has been set (FLG=1), the monitoring unit10determines whether the flag FLG was set at 1 in the previous loop, that is, whether FLGb>0 is satisfied (step S23).

When FLGb>0 is not satisfied, the monitoring unit10adds one to the parameter indicating the occurrences of power supply to the starter motor38(occurrences N: initial value being zero) (step S29). Next, the monitoring unit10determines whether the occurrences N is greater than 2 (step S30).

When the occurrences N is less than or equal to 2, the monitoring unit10sets FLGb=1 (step S26) and then executes the processing in step S27. When the occurrences N is greater than 2, the power supply operation number exceeds its upper limit. Thus, the monitoring unit10stops the power supply from the rechargeable battery40to the starter motor38(step S31). The monitoring unit10terminates the power supply monitoring process and the output control process shown inFIG. 5.

When FLGb>0 is satisfied in step S23, the monitoring unit10adds one to the parameter indicating the power supply time of one occurrence of the power supply to the starter motor38(time Tn: initial value being zero). Next, the monitoring unit10determines whether the time Tn is greater than 2 (step S25).

When the time Tn is less than or equal to 2, the monitoring unit10sets FLGb=1 (step S26) and performs step S27. When the time Tn is greater than 2, the power supply time of one power supply occurrence exceeds its upper limit. Thus, the monitoring unit10performs step S31to stop power supply from the rechargeable battery40to the starter motor38. The monitoring unit10terminates the power supply monitoring process, and also terminates the output control process shown inFIG. 5.

In step S27, the monitoring unit10determines whether the total time T exceeds 10 minutes. When the total time T exceeds 10 minutes, the elapsed time of power supply exceeds its upper limit. Thus, the monitoring unit10performs step S31to stop the power supply from the rechargeable battery40to the starter motor38. The monitoring unit10then terminates the power supply monitoring process and the output control process shown inFIG. 5.

When the total time T is less than or equal to 10 minutes, the monitoring unit10instructs the upper-limit setting unit7to determine whether the engine start signal is still being output from the vehicle ECU20(step S32). Step S32is the same as step S2shown inFIG. 5.

When the engine start signal is still being output, the monitoring unit10instructs the upper-limit setting unit7to set the engine start flag ON (FLG=1) (step S33). When the engine start signal is not being output, the monitoring unit10instructs the upper-limit setting unit7to unset the engine start flag OFF (FLG=0) (step S34). Afterwards, the monitoring unit10performs step S22and the subsequent steps.

In the example ofFIG. 6, the time required for a loop process from when step S22is performed to when step S22is performed again is set at one second. However, the time of the loop process should not be limited to one second. The process shown inFIG. 6may be performed separately from the process shown inFIG. 5. This prevents unnecessary draining of the rechargeable battery40when the engine is abnormal and cannot be started. In this case, the upper limits for the power supply occurrences, the power supply time for each power supply occurrence, and the elapsed time may be set to values differing from the above-described values.

As described above in the first embodiment, even when the short-term output upper limit Pp is less than the power value α, the minimum power required to start the engine is ensured. Thus, even when the terminal voltage of the rechargeable battery decreases under low temperatures in the first embodiment, power is supplied to the starter motor38. This ensures the starting of the engine.

In the first embodiment, the starter motor38is not intermittently turned on and off. Thus, unlike in the prior art, the discharge voltage of the rechargeable battery does not repeatedly increase and decrease within a short period of time. When the short-term output upper limit Pp is set equal to the power value α as shown inFIG. 4, the terminal voltage of the rechargeable battery40decreases. However, the damage of the rechargeable battery40inflicted by this decrease in the terminal voltage is smaller than the damage of the rechargeable battery inflicted in the prior art. Thus, compared with the prior art, deterioration in the rechargeable battery of the first embodiment is more suppressed.

In the first embodiment, the monitoring unit10monitors the power supply to the starter motor38. This further prevents deterioration of the rechargeable battery. In the first embodiment, when the terminal voltage of the rechargeable battery decreases after the vehicle is activated, either one or both of the short-term output upper limit Pp and the long-term output upper limit Pn is lowered. As a result, the rechargeable battery is prevented from deteriorating even after the vehicle is activated.

In the prior art, power is supplied to the starter motor only after the terminal voltage of the rechargeable battery increases to or above the minimum voltage. Thus, the engine may not be started in some cases. Such a case is avoided in the first embodiment since the terminal voltage of the rechargeable battery is not a requirement that must be satisfied to start the engine.

The processes shown inFIG. 5andFIG. 6may be provided as computer programs. The computer programs may be installed in a microcomputer included in the battery ECU1and be executed by a central processing unit (CPU) incorporated in the control circuit5. In this case, the voltage measurement unit4may be formed by a connection circuit of the voltage sensor and the CPU, the current measurement unit2may be formed by a connection circuit of the current sensor44and the CPU, the temperature measurement unit3may be formed by a connection circuit of the temperature sensor43and the CPU, and the storage unit6may be formed by a memory incorporated in the microcomputer.

When the electric vehicle is an HEV, the vehicle ECU may also function as the battery ECU. In this case, the battery ECU1of the first embodiment may be realized by installing programs of the processes shown inFIG. 5andFIG. 6into a microcomputer forming the vehicle ECU20and executing the programs.

A rechargeable battery controller and a method for controlling output of a rechargeable battery according to a second embodiment of the present invention will now be described with reference toFIG. 7.

The rechargeable battery controller of the second embodiment will first be described. The rechargeable battery controller (battery ECU) of the second embodiment differs from the rechargeable battery controller of the first embodiment in the processing performed by a upper-limit setting unit7. The remaining structure of the rechargeable battery controller of the second embodiment is the same as the structure of the first embodiment.

When the engine is started, the upper-limit setting unit7in the second embodiment resets (raises) the set upper limits when the third requirement described below is satisfied in addition to the above first and second requirements. The second embodiment differs from the first embodiment in this point. The short-term output upper limit Pp is reset also in the second embodiment.

The third requirement is that the terminal voltage of the rechargeable battery40is greater than or equal to the reference voltage V1(refer toFIG. 4). The upper-limit setting unit7compares the minimum terminal voltage Vu_min with the reference voltage V1, and determines that the third requirement is satisfied when the minimum terminal voltage Vu_min is greater than or equal to the reference voltage V1.

In the second embodiment, the storage unit also stores a map showing the relationship between the temperature and the optimum reference voltage V1. The upper-limit setting unit7locates the lowest battery temperature and sets the reference voltage V1by comparing this temperature with a map. The map is also generated to reflect the capacity or load the rechargeable battery40based on the results of discharging experiments conducted in advance. To determine the reference voltage V1when generating the map, a critical voltage (V21) that does not affect the life of each battery cell is first obtained through discharging experiments. A margin is then added to the critical voltage in a manner that none of the battery cells changes its poles. The margin is set to consider variations between the battery cells and also to consider the effects that are caused when the battery cells are left unused.

The method for controlling output of the rechargeable battery in the second embodiment will now be described. The rechargeable battery output control method according to the second embodiment is used by the battery ECU1. InFIGS. 5 and 7, like steps are given the same reference numerals.

As shown inFIG. 7, the upper-limit setting unit7performs the processing in steps S1to S3in the same manner as in the first embodiment. When the short-term output upper limit Pp is determined as being greater than or equal to the power value α required to drive the starter motor in step S3, the communication unit outputs the short-term output upper limit Pp set in step S1and the long-term output upper limit Pn set in step S1to the vehicle ECU as the short-term output information and the long-term output information.

When the short-term output upper limit Pp is less than the power value α, the upper-limit setting unit7further determines whether the minimum terminal voltage Vu_min is greater than or equal to the reference voltage V1(step S9). When the minimum terminal voltage Vu_min is less than the reference voltage V1, the rechargeable battery may deteriorate if power is supplied to the starter motor. In this case, the upper-limit setting unit7resets the short-term output upper limit Pp to zero and rewrites the short-term output information (step S10).

Afterwards, step S8is performed and the communication unit outputs the short-term output upper limit Pp reset in step S10and the long-term output upper limit Pn set in step S1to the vehicle ECU as the short-term output information and the long-term output information.

When the shortest terminal voltage Vu_min is greater than or equal to the reference voltage V1, the upper-limit setting unit7resets the short-term output upper limit Pp in the same manner as in the first embodiment and raises the short-term output upper limit Pp to the power value α required to drive the starter motor (step S4). The upper-limit setting unit7rewrites the short-term output information. Further, the upper-limit setting unit7performs the processing in steps S5to S7in the same manner as in the first embodiment. When the engine start signal is not being output (FLG=0) in step S2, the engine has already been started and the vehicle has been activated. Thus, the upper-limit setting unit7performs the processing in steps S11to S15in the same manner as in the first embodiment.

As described above in the second embodiment, even when the short-term output upper limit Pp is less than the power value α, the minimum power required to start the engine is ensured in the same manner as in the first embodiment. This ensures starting of the engine. Like in the first embodiment, the starter motor is not turned on and off intermittently. Thus, deterioration of the rechargeable battery is further prevented as compared with the prior art.

Further, the reference voltage V1is set in the second embodiment. When the shortest terminal voltage V_min of the rechargeable battery is less than the reference voltage V1, power is not supplied to the starter motor. Thus, deterioration of the rechargeable battery in the second embodiment is further prevented as compared with the first embodiment.

In the second embodiment, the battery ECU may be realized by installing a program of the processes shown inFIG. 7to a microcomputer and executing the programs.

A rechargeable battery controller and a method for controlling output of a rechargeable battery according to a third embodiment of the present invention will now be described with reference toFIGS. 8 and 9. The rechargeable battery controller (battery ECU) of the third embodiment differs from the rechargeable battery controller of the first embodiment in the processing performed by the upper-limit setting unit7. The remaining structure of the rechargeable battery controller of the third embodiment is the same as the first embodiment.

In the third embodiment, the upper-limit setting unit7resets (raises) the set upper limits when the fourth requirement described below is satisfied in addition to the first and second requirements during the starting of the engine. The third embodiment differs from the first embodiment in this point. The short-term output upper limit Pp is also reset in the third embodiment.

The fourth requirement is that the SOC of the rechargeable battery40is greater than or equal to the reference SOV. The upper-limit setting unit7compares the SOC estimated by the calculation unit with the reference SOC and determines that the fourth requirement is satisfied when the SOC estimated by the calculation unit is greater than or equal to the reference SOC. The reference SOC is exemplified as REF inFIGS. 8 and 9, which will be described later.

In the third embodiment, the storage unit also stores a map showing the relationship between the temperature and the optimum SOC. The upper-limit setting unit7locates the lowest battery temperature and sets the reference SOC by comparing the temperature and the map. The map is also generated to reflect the performance of the rechargeable battery40or the load of the rechargeable battery40based on the results of discharging experiments conducted in advance. To determine the reference SOC when generating the map, a critical SOC that does not affect the life of each battery cell is first obtained through discharging experiments. A margin is then added to the critical SOC in a manner that none of the battery cells changes its poles. The margin is set to consider variations between the battery cells and also to consider effects that are caused when the battery cells are left unused.

A method for controlling output of the rechargeable battery in the third embodiment will now be described with reference toFIGS. 8 and 9. The rechargeable battery output control method of the third embodiment is used by the battery ECU1. InFIGS. 8 and 5, like steps are given the same reference numerals.

As shown inFIG. 8, the upper-limit setting unit7first performs steps S1to S3in the same manner as in the first embodiment. When the short-term output upper limit Pp is determined as being greater than or equal to the power value α required to drive the starter motor in step S3, the communication unit outputs the short-term output upper limit Pp set in step S1and the long-term output upper limit Pn set in step S1to the vehicle ECU as the short-term output information and the long-term output information.

When the short-term output upper limit Pp is less than the power value α, the upper-limit setting unit7further determines whether the SOC of the rechargeable battery is greater than or equal to the reference SOC (REF) (step S16). When the SOC of the rechargeable battery is less than the reference SOC (REF), the upper-limit setting unit7resets the short-term output upper limit Pp to zero in the same manner as in the second embodiment and rewrites the short-term output information (step S10).

After step S10is performed, step S8is performed. As a result, the communication unit outputs the short-term output upper limit Pp reset in step S10and the long-term output upper limit Pn set in step S1to the vehicle ECU as the short-term output information and the long-term output information.

When the SOC of the rechargeable battery estimated by the calculation unit is greater than or equal to the reference SOC (REF), the upper-limit setting unit7resets the short-term output upper limit Pp in the same manner as in the first embodiment as shown inFIG. 9and raises the value of the short-term output upper limit Pp to the power value α required to drive the starter motor (step S4). Here, the upper-limit setting unit7rewrites the short-term output information. Further, the upper-limit setting unit7performs steps S5to S7in the same manner as in the first embodiment. When the engine start signal is not being output (FLG=0) in step S2, the engine has been already started and the vehicle has been activated. In this case, the upper-limit setting unit7performs steps S11to S15in the same manner as in the first embodiment.

As described above in the third embodiment, even when the short-term output upper limit Pp is less than the power value α, the minimum power required to start the engine is ensured like as in the first embodiment. This ensures the starting of the engine. In the first embodiment, the starter motor is not turned on and off intermittently. Thus, deterioration of the rechargeable battery is further prevented as compared with the prior art.

Further, the reference SOC is set in the third embodiment. When the SOC of the rechargeable battery is less than the reference SOC, power is not supplied to the starter motor. This further prevents deterioration of the rechargeable battery as compared with the first embodiment.

In the third embodiment, the battery ECU may be realized by installing programs of the processes shown inFIG. 8on a microcomputer and executing the programs.

The rechargeable battery output controller and the rechargeable battery output control method of the present invention are applicable to any rechargeable battery for supplying power to a starter motor of a vehicle and are applicable not only to an HEV but also to an automobile using a normal engine.

It should be apparent to those skilled in the art that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalence of the appended claims.