Secondary service port for high voltage battery packs

A system and method for providing energy management and maintenance of a high energy battery pack that does not require installation of the battery pack into an operational EV. A secondary service port is provided to enable certain maintenance operations while by-passing battery pack interlocks and protection mechanisms used when the battery pack is installed into an operating environment.

FIELD OF THE INVENTION

The present invention relates generally to charging and discharging energy storage systems, and more specifically, but not exclusively, to energy maintenance and management of high-voltage battery packs useable in electric vehicles (EV) through a service port.

BACKGROUND OF THE INVENTION

Battery packs used with electric vehicles store large amounts of energy in a small space, producing high energy densities. These battery packs include an external housing that is designed for more than just environmental protection and packaging efficiency. The housing also enhances safety and stability, particularly under a range of anticipated abnormal operating conditions.

Due to the high energy densities involved, it is known to provide internal safety mechanisms to help ensure that stored energy is controllably released under a narrow set of circumstances. These safety mechanisms interact with mechanical and electrical interfaces provided by an operational vehicle to enable energy charging and discharging.

There are a wide range of situations where energy maintenance and management of a battery pack is needed, and not all of these include situations where the battery pack is installed in a vehicle or a vehicle known to be 100% operational. Some of these situations include storage, transport, and recycling of a high energy battery pack where the battery pack is not installed in an EV. Other situations include operations on a battery pack that is installed in an EV, but the circumstances indicate that operation of the EV, or a subsystem thereof, may be degraded. Degradation may occur from collisions or acts of nature and could compromise a safety system of the battery pack. Even when the safety system is not actually compromised, the state of the vehicle or its environment or status may indicate that there is a risk that the safety system has been compromised. In those situations, it may not be reasonable to expect that the vehicle may be available to provide the necessary interface and safety structures. Of course, there are also situations where maintenance and management operations are needed with respect to a fully functional EV and battery pack.

Maintenance and management operations include charging and discharging a battery pack safely to desired state of charge (SOC) levels. Depending upon the situation, the desired SOC level could require a discharging or a charging operation. Under some circumstances, it is necessary or desirable to perform the operation without benefit of the battery pack being installed into an EV, nor is it always economical or possible in every case to provide an operational EV into which the candidate battery pack may be installed.

One of the incorporated co-pending patent applications includes a discussion of a charging/discharging tool that advantageously under certain circumstances has access to a high-voltage battery pack through a secondary service connection. Sometimes it is the case that the primary service connection is unavailable while there is significant stranded energy present. These cases may include damage to the primary service connection, internal fault with the energy storage system, and/or damaged or defective internal connections.

Even in situations when the primary service connection is available, use of a charging/discharging tool through this connection may add undesired costs and complexities under some scenarios. In order to operate the primary service connection typically used by an electric vehicle, the charging/discharging requires costly CAN communication, special connectors, time to disconnect the vehicle electrical connector and install the connector to the external device, and configuration/use of any simulator to emulate conditions of the operating environment in cases where there is are failsafe protections inhibiting direct access by such a tool.

An energy storage system installed in an EV with significant stranded energy may be implicated by first responders (e.g., fire fighters, security, and emergency personnel) and second responders (e.g., tow truck drivers, dismantlers, junk yards, and auto-salvagers). Whether there is a need for rapid response or access by persons who may lack monetary resources, training, or technical background to address the stranded energy through the primary service connection using a specialized and sophisticated charging/discharging tool, it can be problematic when access the energy storage system is limited.

What is needed is an apparatus and method for providing energy management and maintenance of a high energy battery pack through use of a secondary service port.

BRIEF SUMMARY OF THE INVENTION

Disclosed is a system and method for providing energy management and maintenance of a high energy battery pack through use of a service port. There is a need to manage battery packs that have been removed from their operating environment (e.g., an EV) due to some loss of normal functionality and the secondary service port is one modality for meeting that need, for the battery pack out of, or installed in, its operating environment.

The following summary of the invention is provided to facilitate an understanding of some of technical features related to energy management and maintenance of a high energy battery pack, and is not intended to be a full description of the present invention. A full appreciation of the various aspects of the invention can be gained by taking the entire specification, claims, drawings, and abstract as a whole. The present invention is applicable to battery packs whether installed into an operating environment, as well as other operating environments in addition to the EV environment.

A rechargeable high-voltage battery pack, including: a plurality of series-coupled energy storage elements; an interlock having a first node and a second node, the first node coupled to the plurality of series-coupled energy storage elements with the interlock responsive to a control signal to control a power communication of the first node to the second node, the interlock enabling the communication with the control signal in a first mode and the interlock disabling the power communication with the control signal in a second mode; a housing enclosing and sealing the plurality of series-coupled energy storage elements and the interlock with a plurality of exterior walls; an operational port coupled to a portion of a first particular one exterior wall of the plurality of exterior walls, the operational port coupled to the second node and providing a first energy transfer with respect to the plurality of series-coupled energy storage elements only when the power communication is enabled; and a service port coupled to a portion of a second particular one exterior wall of the plurality of exterior walls, the service port coupled to the first node and providing a second energy transfer with respect to the plurality of series-coupled energy storage elements without regard to whether the power communication is enabled.

A method for managing a rechargeable high-voltage battery pack, including: a) configuring the rechargeable high-voltage battery pack to transfer energy with respect to an exterior operational port through an interlock; and b) bypassing the interlock to transfer energy between the rechargeable high-voltage battery pack and an exterior service port without using the operational port to transfer energy relative to the rechargeable high-voltage battery pack.

Embodiments include a method and system for charging and discharging high-voltage battery packs when the supporting operating environment (e.g., an EV) is not operational and it is not known whether the battery pack is operating properly or has been compromised due to external damage, internal failure of batteries or other similar situations.

Some of the disclosed embodiments define and include a dedicated service port that allows for an electrical connection to the battery pack that is independent of CAN communication, separate from the electrical connection to the operating environment, and not required to simulate the some aspect of that environment (e.g., drivetrain electrical signature). A dedicated service port with direct access to a cell side of battery contactors of the battery pack would also simplify the complexity of an external discharge tool to allow it to more easily work across multiple vehicle designs.

Some embodiments of the present invention include one or more of:1) A configuration allowing access to battery high voltage independent of BMS controls, contactors, or relays, such for a) discharging non-functional battery;b) checking isolation of non-functional battery; and c) checking SOC of non-functional battery;2) An inline diode or other current-flow-direction control on either or both a positive side or negative rail to only allow discharge (and thereby preventing a dangerous overcharging condition of the battery pack);3) An inline fuse to limit discharge rate on either or both the positive side or negative rail;4) A Thermal control feature for heat generated by inline diode rejecting heat to a thermal mass of high voltage conductors, battery enclosure, or battery liquid or air cooling loop;5) A tamper evident seal securing the service port to minimize non-intended use(s);6) An interface paradigm to the service port that requires special tools to access to reduce non-intended use(s);7) A dynamic/reactive seal for the service port to secure it during non-active use, thereby reducing moisture or foreign object ingress; and8) An interface paradigm that grounds a chassis of the battery pack upon engagement of the service port interface (e.g., insertion of a plug of a service unit into a receptacle of the service port) prior to making electrical contact with pins coupled to stored energy.

Some embodiments include tamper-evidence technology to minimize or prevent general use of or tampering with the service port because improper use of the service port may damage the battery pack or otherwise be a basis for voiding a warranty associated with the operating environment. Embodiments of the present invention contemplate use of the service port in association with specific service actions. A tamper evident label and/or use of warning technology discourage non-authorized use.

Depending upon implementation, some embodiments provide an external device with electrical access to an otherwise sealed, non-operational battery: i) after a crash event to remove stranded energy; ii) prior to transport (shipment) to reduce the amount of stored energy or to meet regulatory requirements; iii) prior to remanufacturing to reduce a working voltage or to reduce an amount of stored energy; and iv) in other scenarios where an SOC or isolation resistance of the energy storage system is to be determined. A service port enables these operations without regard to whether a functional battery pack is installed in an intact operating environment.

The electrical connection typically used by the vehicle may no longer be operational due to physical damage, an internal battery fault, or damaged or defective relays or contactors internal to the battery.

Other features, benefits, and advantages of the present invention will be apparent upon a review of the present disclosure, including the specification, drawings, and claims.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention provide a system and method for providing energy management and maintenance of a high energy battery pack installed in an EV through use of a service port. The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements.

In the following detailed description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of the various embodiments of the present invention. Those of ordinary skill in the art will realize that these various embodiments of the present invention are illustrative only and are not intended to be limiting in any way. Other embodiments of the present invention will readily suggest themselves to such skilled persons having the benefit of this disclosure.

In addition, for clarity purposes, not all of the routine features of the embodiments described herein are shown or described. One of ordinary skill in the art would readily appreciate that in the development of any such actual implementation, numerous implementation-specific decisions may be required to achieve specific design objectives. These design objectives will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would nevertheless be a routine engineering undertaking for those of ordinary skill in the art having the benefit of this disclosure.

A battery service unit capable of simulating an operating environment of a high-voltage battery pack (e.g., simulating an EV) to enable charging and discharging of the battery pack has numerous advantages. When the battery pack is not installed in the operating environment, installed in the operating environment under circumstances in which the operating environment may be degraded and possibly unreliable, or installed in an uncompromised environment, the battery service unit enables predictable and safe management and maintenance operations of the SOC.

Rechargeable battery packs require management and maintenance to set desired SOC levels. What the precise SOC level is depends upon the construction and nature of the energy storage elements making up the battery pack (e.g., type(s) of cell chemistry used in battery cells) and what operation the battery pack is expected to perform. For high-voltage battery packs that are assembled from tens, hundreds, and sometimes thousands of Lithium-ion energy storage elements arranged in parallel/series combinations, there are SOC levels and ranges that are optimum for various operations. In some cases, optimum SOC levels are set to minimally impact battery pack life expectancy. In some cases, an optimum SOC level is set to minimize risk of injury to persons and property in the vicinity of a battery pack and persons servicing the battery pack.

Embodiments of the present invention provide a single battery service unit applicable to this wide range of possible scenarios. Other embodiments could be specialized for a limited set of scenarios, and sometimes a single scenario. These scenarios include discharging/charging the battery pack in anticipation of: 1) storage; 2) transportation; 3) recycling; and 4) service. Storage ideally sets the SOC appropriate for maximizing life expectancy. During storage, a battery pack will lose charge and periodically the battery pack will need to be charged to maintain the SOC at the desired level. There are safety guidelines and legal requirements for transportation of a battery pack and the battery service unit is used to set the SOC appropriate for transport. Prior to recycling, it is desirable to remove as much energy as possible from the battery pack. The service scenario includes many different situations, including: a) servicing of the battery pack outside of its operating environment, b) servicing of the battery pack when installed in an operating environment that may be compromised due to an event that has or had the potential to induce damage to the battery pack where the battery pack or the supporting operating environment may be partially or wholly inoperative, and c) servicing of the battery pack in an intact and functioning operating environment.

When the operating environment includes an intact and functional EV, the battery service unit is able to leverage existing hardware/software infrastructure, such as a battery management system, to safely diagnose the state of a vehicle and then proceed to charge or discharge the battery pack as deemed appropriate under the circumstances. In the event the electric vehicle has been in a collision or subjected to other potentially damaging event (e.g., flooding), the battery service unit is used by a responder or other service professional to safely discharge the battery pack. Use of the battery service unit places the battery pack in a safer state allowing the vehicle to be moved or repaired with decreased risk.

Additionally, some embodiments of the battery service unit may also be used by service professionals to provide routine services related to maintenance and management of the EV. The battery service unit may include programmatic steps that guide the service professional through various functions for ensuring the battery pack is charged to proper levels and the battery management system is working correctly.

In the discussion herein, embodiments of the present invention are described as determining a desired SOC level and automatically setting an SOC level of an energy storage system to the desired SOC level. In some scenarios, the embodiments rely on an operating environment of the energy storage system to provide the current SOC information, and in other instances an external service unit determines (through measurement, calculation, or estimation) the current SOC level. Some embodiments transfer energy with respect to the ESS to automatically set the actual SOC level to the desired SOC level within a predetermined threshold.

The following discussion also includes reference to high voltage and high energy. In the context of the present invention, high voltage is a voltage exceeding 40 V. High energy in this context includes battery packs storing 10 kWh or more, though other embodiments may define high energy with a different energy capacity or capacity threshold.

FIG. 1illustrates schematically an operating environment100including an electric vehicle (EV)102having a high-voltage battery pack104coupled to a battery service unit106. Operating environment100is relevant to scenarios including fully intact EV102as well as situations in which EV102may be partially or wholly compromised. EV102includes a primary high-voltage (HV) port108for energy transfer and an associated digital control interface110as well-known. Primary HV port108provides a standard electromechanical interface for safely transferring charging energy from a charging station to battery pack104. Associated with primary HV port108is digital control interface110for use by the charging station to monitor and control charging. Battery service unit106includes a complementary electromechanical interface to access battery pack104through primary HV port108and digital control interface when they are available and operational.

EV102further includes a secondary HV port112for direct management and maintenance access to battery pack104. There are many possible implementations for the electromechanical interface of secondary HV port112and its interaction with battery pack104. Some of the interface components and interactions are described herein. The discussion herein including the description ofFIG. 7provides further details of a representative secondary HV port112.

Battery service unit106includes a high-voltage battery service interface114coupled to a high-voltage charger unit116through a high-voltage connection (HV) and control line (CTL) such as RS-232 communication protocol. In addition, battery service unit106further is coupled to a high-voltage discharger unit118also through a high-voltage (HV) connection and another control line (CTL) such as a digital communication interface like CAN-IO (Controller Area Network Input/Output), widely used in the automotive industry. An optional controller120(e.g., a computer or the like) interacts with battery service interface114using a digital control interface adapter122that also may produce signals compatible with CAN-IO. Instructions executing on controller120oversee operation of high-voltage battery pack104as well as charger unit116and discharger unit118, as appropriate. Controller120may be integrated into battery service unit106in addition to implementations including an external element. Battery service unit106may include interface elements providing some control capability of battery service interface114, charger unit116, and discharger unit118independent of controller120.

Charger unit116operates as a conventional charger appropriate for battery pack104. Embodiments of the present invention provide a maximum charging rate of 1 kW, though other implementations may provide other charging rates. Discharger unit118includes energy dissipative and/or transformative elements (e.g., resistors) that absorb energy discharging from battery pack104using battery service unit106without damage or risk of injury. Embodiments of the present invention provide a maximum discharging rate of 10 kW, though other implementations may provide other discharging rates.

In the embodiment ofFIG. 1, battery service unit106receives operational power from a power source124. Power source124includes AC line power (e.g., grid or generator power) and DC battery power to power and control battery service unit106. Battery service unit106is designed to support the wide range of scenarios and situations described herein and as such, some of those situations do not include predictable and easy access to stored energy of battery pack104(assuming that there is sufficient energy stored in the battery pack). To ensure that battery service unit106is useable in any context, it includes its own power source. In some implementations, battery service unit106may be powered, or charged, in whole or part by energy from battery pack104.

An embodiment of battery service unit106includes: 1) a discharger (a fixed resistive load bank or an electronic load); 2) a variable voltage constant current or constant voltage power supply; 3) a controller; 4) a drive Inverter Simulator (e.g., capacitor); 5) an active discharge circuit for onboard capacitors—a. has redundant circuits for safety and reliability and b. automatically triggered via E-Stop, or when any HV cable is disconnected; 6) a passive discharge circuit for onboard capacitors; 7) a current sensor; 8) a method to protect contactors from opening under load; 9) a user configurable SOC (state-of-charge); 10) a method to conduct a Capacity Test; 11) a method to charge or discharge a battery to an appropriate level per regulatory shipping requirements; 12) an over voltage protection; 13) an under voltage (over discharge) protection; 14) an over temperature protection; 15) a voltage measurement display; and 16) status LED indicators.

Other features of selected embodiments of the present invention include: 1) a configurable HV bus capacitance (allows the battery service unit to work with batteries from a variety of powertrains); 2) a configurable low-voltage input board—a. low voltage signals vary from product to product: different connectors, different voltages, different expected resistances, by having a configurable and expandable low voltage input to the battery service unit it is capable of handling multiple products with only a different cable attachment; 3) all relays, sensors, and internal devices controlled over CAN (allows easy communication from one device to the next as the CAN messages are changed as necessary); 4) may be implemented as a mobile product, to allow deployment at vehicle service centers or roadside assistance (post vehicle crash event for example) or throughout a storage facility and the like; 5) a configurable voltage range to work across battery product lines; and 6) implemented as a module discharge system to work across battery product lines.

A general description of operation includes battery service unit106coupling to battery pack104(whether installed or non-installed in an operating environment) and auto-charging/discharging battery pack104to a predefined user determined SOC level.

InFIG. 1, the embodiment is illustrated as having direct functional connections between HV battery pack104and battery service unit106. In various implementations, there may be one or more wiring harnesses and connectors (for example, at the signal/mechanical interfaces of EV102).

FIG. 2illustrates schematically selected subcomponents of high-voltage battery service interface114illustrated inFIG. 1. High-voltage battery service interface114includes a high-voltage battery service communications interface200, a digital control signaling module202, a digital control interface switch204, a set of high-voltage terminals206, and various interconnects to other systems including a high-voltage power supply connector208, a high-voltage load bank connector210, a high-voltage primary/secondary HV port connector212for connection to high-voltage battery pack104, a digital I/O module214for connection to adapter122(e.g., a dongle), and a digital control interface port216. The connection to the personal computer uses digital I/O module214having a USB (universal serial bus) connection to controller120and a digital I/O connection to high-voltage battery service communications interface200compatible with the CAN-IO standard or similar protocol. High-voltage battery service interface114includes a digital control interface port216, an emergency shut-off switch218, and an on-off switch220, as well as one or more internal digital I/O connectors222and one or more external digital I/O connectors224.

Interface200further includes an operating environment simulator226, a set of charge/discharge relays228, and a high-voltage discharge logic and load230. Simulator226is implementation specific and includes a combination of components that create an electrical characteristic composite or “signature” matching the intended operating environment of battery pack104, such as an EV. Simulator226mimics the operating environment and provides battery pack104with the necessary interface elements (e.g., electrical signals and loads) to enable battery pack104to transition into an operational mode. For example, battery pack104commonly includes internal contactors that must be powered and set into a particular configuration before battery pack104may transfer energy. Simulator226enables battery service unit106to operate such high-voltage contactors so charging or discharging may be possible. In some embodiments, simulator226includes various capacitors and/or inductors matching the impedance of the operating environment and, when combined with predetermined resistors within battery pack104, producing time constants that may be identified with a particular vehicle. Battery pack104is receptive to receiving various commands once it is in the operational mode. In the implementation illustrated inFIG. 2, simulator226is capable of being reconfigured to simulate different operating environments.

In operation, high-voltage battery service communications interface200receives low-voltage inputs from battery pack104over digital control interface port216once communication is established. In some embodiments, controller120may send digital commands over digital control interface switch204and to digital control signaling module202to toggle status in the battery pack indicating the car is in a specific state (e.g., a “DRIVE” state), without regard to whether the operating environment is currently able to support the specific state. Charging battery pack104may be achieved by enabling connectors to high-voltage power supply connector208while discharging may occur through enabling connectors to high-voltage load bank connector210, typically one or several banks of resistors maintained in a separate enclosure along with fans or other heat dissipation subcomponents.

FIG. 3illustrates a schematic design for a battery pack including a primary HV port and a secondary HV port used by the battery service unit in accordance with some embodiments of the present invention.FIG. 3illustrates a battery pack300including a plurality of electrically-serially-coupled battery modules302contained within a high-voltage battery enclosure305. Battery pack300further includes a current sensor310, a fuse315, a set of contactors320, a battery management system (BMS)325, a primary power connector (e.g., primary HV port108), a control interface (e.g., digital control interface110) and secondary power connector (e.g., secondary HV port112). Enclosure305typically provides a structural\environmental container (sometimes hermetically closed or semi-sealed) for battery pack300components. Battery pack300often includes a coolant distribution system (generically represented by coolant loop335and pump340) isolated and insulated from the battery pack300components and configured to control their temperature. As will be further described herein, pump340(or other coolant controller) is preferably powered by energy from an auxiliary energy storage system345(typically a 12V battery) different from battery pack300. Interrupting available energy from battery pack300would interrupt coolant flowing in coolant loop335without use of auxiliary energy storage system345. For ease in explanation, a discrete controller350is also shown for interfacing with BMS325, pump340, and auxiliary energy storage system345to control the detection and response modalities of the preferred embodiments. Controller350may be integrated into other control functions in some embodiments.

Battery pack300may include any number of modules302different from the five shown inFIG. 3. Modules302are serially-coupled inside enclosure305with a series path shown in solid lines. In series with serially-coupled modules302is current sensor310, fuse315, and contactors320. Current sensor310measures series current in battery pack300. When battery pack300is working properly, all modules302exhibit the same current and current sensor310indicates this value. Fuse315is disposed in this series path and is designed to protect against over current conditions.

Contactors320are switching systems for selectively communicating modules302to an external load through the primary power connector. Battery management system (BMS)325controls contactors320and includes controllers and sensors for measuring and determining desired parameters (e.g., operating and SOC characteristics and the like) of battery pack300. As previously mentioned, BMS325will generally close contactors320when battery service unit106provides a proper electrical signature of an appropriate operating environment. The provision of the signature causes the BMS325to operate as if battery pack300is actually installed in a valid and intact operating environment. The secondary power connector, optionally also coupled to the “cell side” of contactors320, are used as an alternative energy access port (e.g., the secondary HV port/service port described herein). In some embodiments, the secondary power connector is used to provide a service access port for direct charging and/or discharging operations of battery pack300such as when some or all portions of the battery pack300are compromised and/or when BMS325also is not operable and cannot close contactors320.

Battery pack300further includes current protection devices360(e.g., fuses) limiting energy flow relative to the secondary power connector332. Some embodiments further include a diode365or the like to limit energy flow in one direction, such as ensuring that the alternative energy access port may be used for one of charging or discharging only.

While great care is used in designing, manufacturing, and testing battery pack300, sometimes it is the case that an internal short355may develop among one or more of the series elements. In some cases, these shorts may be the result of a vehicle being in a collision, a catastrophic event (natural or man-made), or general wear or failure. Representative internal shorts355are shown in dashed lines inFIG. 3, but it is understood that internal shorts may develop elsewhere, including internal shorts contained within a series stackup of module302. One or more of the implicated series elements sourcing current through internal short355contribute current through the intended series path as well as through internal short355. These series elements can thus begin to exhibit sustained high levels of current that may lead to component over-temperature, failure, and sometimes a hazard. This is sometimes further complicated as the object(s) which formed all or part of the short circuit may also create dangerous heat/temperatures.

Internal short355may occur between adjacent high voltage (HV) chain components at different potentials or through the conductive, isolated enclosure in the case that isolation is lost at two or more points, or through another medium, such as a conductive fluid such as salt water, water, water/glycol mixtures, and the like. An impedance of internal short355and a number of series elements affected by internal short355determines the short current. In some cases internal short355may be intermittent. Internal short355will have a heat capacity that also helps determine whether internal short355will change its impedance (for example, become open circuit) as internal short355dissipates power. In some embodiments, BMS325reports these conditions to battery service unit106allowing it to determine how to charge or discharge the battery pack300.

When BMS325and battery pack300are intact and operating properly, battery service unit106connects through the primary power connector. This is advantageous as battery service unit106is able to mimic the vehicle's operation in the specific state and utilize BMS325to open and close contactors320in a safe manner minimizing wear and tear on the battery pack and its components. Other control and safety measures available to the vehicle remain available in this mode of operation.

When BMS325and/or battery pack300exhibit one or several faults or failures, battery service unit106may instead engage connections through the secondary power connector thereby bypassing the controls of BMS325. While this alternate approach may be necessary in an emergency situation such as a collision or other event, such discharging of the battery pack300through the secondary power connector may result in partial or severe damage to the underlying battery cells and interconnections.

FIG. 4illustrates an energy transfer for a high-voltage battery pack104in an extra-operational environment400using the primary charging connector. In extra-operational environment400, battery pack104is not installed in its operating environment. Battery service unit106is used to automatically set a desired SOC level for battery pack104. In some embodiments, battery service unit106includes preselected scenarios (e.g., storage, ground transportation, air transportation, recycling, emergency discharge, and the like), each having a predetermined associated SOC level. An operator choosing one of the preselected scenarios causes battery service unit106to automatically charge/discharge battery pack104to the predetermined SOC level associated with the selected scenario.

InFIG. 4, extra-operational environment400configures battery service unit106to discharge HV energy from battery pack104. Battery service unit106provides operational power (e.g., 120-230VAC) from power source124to battery service interface114and to discharger unit118using power lines405. Battery service interface114issues a remote enable signal to discharger unit118using a remote enable signal line410and communicates with and controls battery pack104using a digital I/O line415. Depending upon battery pack104and the interface method, it may be further necessary for battery service unit106to provide simulation information to simulate an operating environment for battery pack104before it may be commanded and/or before an initiation of an energy transfer event. High-voltage lines420couple battery pack104to battery service unit106and internally couple battery service interface114to discharger unit118. Battery service unit106may charge HV energy into battery pack104by coupling charger unit116to battery service interface114and appropriately setting the control signals. In some cases a different mechanical interface (e.g., wiring harness) may be necessary to couple battery service unit106to battery pack104for charging.

FIG. 5illustrates an energy transfer for a high-voltage battery pack104in an extra-operational environment500using the secondary charging connector. In extra-operational environment500, battery pack104is not installed in its operating environment. However the embodiment ofFIG. 5is also applicable to uses in which battery pack104is installed into its operating environment but for one reason or another (such as those described herein) the primary charging connector is not used. Battery service unit106is used to automatically set a desired SOC level for battery pack104. In some embodiments, battery service unit106includes preselected scenarios (e.g., storage, ground transportation, air transportation, recycling, emergency discharge, and the like), each having a predetermined associated SOC level. These SOC levels are set for controlled SOC charging/discharging with an expectation that battery pack104may be operational at conclusion of the charging/discharging event. An operator choosing one of the preselected scenarios causes battery service unit106to automatically charge/discharge battery pack104to the predetermined SOC level associated with the selected scenario, and when possible, doing so in a way that does not negatively affect future performance (e.g., lifetime). Operational environment500further supports an emergency discharge mode in which a primary goal is removal of stranded energy of battery pack104, sometimes as quickly as possible. Under this mode, risks of damage to battery pack104are increased. Some embodiments of the present invention provide more safety features for energy transfer using the primary port and more robust options for energy transfer using the secondary port.

InFIG. 5, extra-operational environment500configures battery service unit106to discharge HV energy from battery pack104directly through discharger unit118without simulation or communication with respect to the battery pack. Battery service unit106provides operational power (e.g., 120-230VAC) from power source124to discharger unit118using power line405. High-voltage lines420couple battery pack104to battery service unit106and internally couple battery service interface114to discharger unit118. Battery service unit106may charge HV energy into battery pack104by coupling charger unit116to battery pack104using the secondary HV connector. In some cases a different mechanical interface (e.g., wiring harness) may be necessary to couple battery service unit106to battery pack104for charging.

The disclosed embodiments of battery service unit106anticipate a wider range of uses for discharging a battery pack104. These uses depend upon whether battery pack104and/or its operating environment is intact and operational. For a functional battery pack104, there are three discharge options: 1) use processes and devices of the operating environment to natively discharge energy which may be automatically commanded by battery service unit106; 2) battery service unit106discharges battery pack104as described inFIGS. 4; and 3) battery service unit106commands battery pack104to self-discharge as described in the incorporated patent application. Options 1 and 2 are configured to have a preferred discharge rate of ˜10 kW and a range of discharge rates 1-20 kW (vehicle or load bank) and option 3 has a preferred discharge rate of ˜10 W and a range of discharge rates 5-50 kW. In option 1, the operating environment of an EV includes cabin temperature controls (e.g., heater, air conditioner with HVAC compressor), powertrain coolant system, and low voltage loads (e.g., headlights). One or more of these systems may be enabled and actuated by battery service unit106to have the operating environment discharge battery pack104. This is distinguished from option 3. In option 3 the discharging elements are contained within battery pack104while in option 1, the discharging elements are outside of battery pack104but within its operating environment. Option 2 provides the discharging elements outside of the operating environment. Some implementations may include a combination of options.

While specific details of preferred structures and methods for self-discharge are described in the incorporated self-discharge patent application, in general self-discharge refers to use of power dissipative elements of battery pack104to intentionally discharge energy and decrease availability for standard EV operation which is contrary to the typical systems which try to conserve/preserve energy for operational power uses. Battery pack104typically includes power conserving features and some embodiments of the present invention include an ability to override or limit the power-conserving features to dissipate power. In some cases the power dissipation is maximized and may compromise or damage battery pack104and in other cases the self-discharging power dissipation is maximized while also preserving future operation of battery pack104. The internal power dissipative elements include processors, transmitters, and other elements that can collectively dissipate significant power when operated in the non-power conserving modes. In some embodiments, for self-discharge of battery pack104or when the operating environment uses dissipative elements outside of battery pack104, the coolant system is enabled as heat is rejected into the circulating coolant to reduce risk of discharging events. In some situations, intentional shorts are created into the coolant in order to induce energy-consuming processes (e.g., hydrolysis).

For a non-functional battery pack104, there are also three discharge options: 1) battery service unit106discharges battery pack104as described inFIG. 5with a preferred discharge rate of ˜6 kW and a range of discharge rates 1-6 kW; 2) battery service unit106commands battery pack104to self-discharge as described in the incorporated patent application; and 3) service personnel travel to onsite of battery pack104to safely discharge it manually.

FIG. 6illustrates a flowchart of a discharge process600for a non-functional battery pack104. Process600includes step605—step630. Process600begins at step605to test whether communication with BMS325is possible. When communication with BMS325is possible, process600next performs a test at step610to determine whether it is possible to communicate with all modules302. When communication with all modules302is possible, process600commands battery pack104to perform a self-discharge option as described in option 2 above. When the test at step610determines it is not possible to communicate with all modules302(e.g., a module failure, wire damage, or the like), process600performs step620for an onsite manual discharge as described above in option 3. When the test at step605determines that it is not possible to communicate with BMS325(e.g., a failure of BMS325or a wire failure or the like), process600performs a test at step625. The test at step625determines whether an internal high-voltage series module chain of modules302is intact. When the test at step625determines that the HV chain is intact, process600performs step630which uses battery service unit106to discharge battery pack104using the discharge port (e.g., the secondary port) as described above in option1. When the test at step625determines that the HV chain is not intact (e.g., a fuse is blown or a cable is damaged, or the like), process600performs step620for an onsite manual discharge.

FIG. 7illustrates an energy management scenario700for high-voltage battery pack104installed into an operating environment705. Operating environment705includes a vehicle, load bank, or other implementation using a rechargeable high energy storage system. An exterior interface to operating environment705includes a primary access710and a secondary access715.

An operator of service unit106has an option to interact with battery pack104installed in operating environment705using either primary access710or secondary access715. Operating environment705includes a first processing system720that is a collection of processing, management, and safety systems. First processing system720includes contactors, fuses, filters, processors/controllers, and the like interposed between primary access710and battery pack104. Some embodiments of operating environment705also optionally include a secondary processing system725associated with a collection of processing, management, and safety systems. Secondary processing system725includes contactors, fuses, filters, processors/controllers (e.g., battery management system), and the like interposed between secondary access715and battery pack104. Some elements may be shared between first processing system720and secondary processing system725.

For some energy management scenarios, battery pack104is physically secured and sealed within an enclosure. For performance and safety reasons, there are limited points of ingress and egress. A primary point of ingress and egress is an operational port730. Operational port730provides controlled access to the energy storage components of battery pack104. There may be contactors, fuses, filters, processors/controllers (e.g., battery management system), and the like controlling energy transfer through operational port730, with those elements also represented by operational port730. Some components may be provided in first processing system720, operational port730, or both. Operational port730includes primary HV port108and digital control interface110.

It is through operational port730that standard charging and discharging events occur. The charging and discharging events are strictly controlled for enhanced safety and maximizing life expectancy for battery pack104without unduly limiting performance. In the context of an EV for the operating environment, some implementations of operational port730must receive a proper signature from operating environment705that represents that battery pack104is properly installed in the operating environment and functioning correctly. Service unit106has the ability to simulate or induce generation of this proper signature to enable energy transfers with respect to operational port730. And in typical operation, rates of energy transfers using operational port730are sharply constrained within predetermined design limits to balance some of the competing interests.

These are some of the reasons that accessing stranded energy from battery pack104using operational port730is sometimes slower and more complex. Further, operating environment705sometimes experiences certain types of events that compromise access and use of primary access710and/or damages first processing system720and/or damages operational port730.

To address any drawbacks with such scenarios, energy management scenario700includes a service port735installed at a strategic location of the enclosure for battery pack104. Failure analyses of operating environment705and construction, layout, and reinforcement of the enclosure identify failure modes and associate service port735at locations that are least likely to be compromised whenever operating environment705experiences an event sufficient to make operational port730unavailable. Unavailability includes complete or partial damage that either makes battery pack104inaccessible or increases risks of accessing battery pack104through primary access710such that the risks exceed a predetermined threshold. Service port735includes secondary HV port112.

In the embodiment illustrated inFIG. 7, service port735is configured in a discharge-only mode to remove or sufficiently reduce any stranded energy within battery pack104. One way, among others, that this may be done is to include a discharge diode in secondary processing system725or service port735that limits energy transfers through secondary access715as discharge-only. This is different from operational port730which is illustrated as supporting bi-directional energy transfers (e.g., charging and discharging). As also discussed herein, some implementations may be configured as charging-only through secondary access715or configured also for bi-directional energy flow.

Service port735differs from operational port730in another respect. Service port735is intended for uses in which operational port730is not available and as such represents a contingent port. As a contingent port, supporting discharge events in potentially extreme situations, complexity is reduced and ease-of-use is increased, all the while preserving safety. One consequence of this reduced complexity is that some of the safeguards regarding constraints on discharging energy transfers (e.g., maximum energy transfer rate, SOC low energy targets and thresholds, and the like) are not present or disabled. These considerations are secondary at best to the goal of removing stranded energy from battery pack104in an emergency/urgent situation.

The reduced complexity enables simpler operation and simpler requirements for service unit106, increasing the accessibility and use in this configuration. In certain cases, such as collision, or emergency/urgent event, then first responders may respond more quickly and second responders may remove stranded energy more simply and a version of service unit106capable of maintaining a desired energy level (including removing stranded energy) for battery pack104is simpler to operate and could be made less costly and thereby increase availability of the service unit106.

Some details of the internal layout of battery pack104are illustrated inFIG. 3, with operational port730associated with the primary power connector and the interface connector and service port735associated with the secondary power connector. Service port735is coupled to a “cell” side of contactors320while operational port730is coupled to contactors320interposed to modules302.

When installed, battery pack104is typically mechanically and electrically secured in operating environment705, such as mounted to a portion of a chassis inside an EV. Operating environment705thus limits easy access to operational port730and to service port735. Operating environment705thus provides electro-mechanical interfaces between primary access710/secondary access715and battery pack104. These electro-mechanical interfaces include conductors (e.g., a plus voltage conductor and a negative voltage conductor) and a common implementation for couplers to such electro-mechanical interfaces is use of plugs having pins that mate to complementary receptacles to provide electrical communication.

Operational port730provides the principal access and its electro-mechanical interface is defined and implemented for frequent use. Primary access710is configured for easy and simple access by the user, such as when charging at a charging station.

Service port735in contrast is intended for specialized limited access. Service port735is coupled into battery pack104differently than operational port730as noted herein, and those differences increase risks to battery pack104whenever service port735is used. For example, it is possible that discharging energy from battery pack104using service port735could disables or severely limits future operation of battery pack104, especially if the discharging event is aggressive (e.g., high energy transfer rate). Some implementations of the mechanical interface provide enhanced grounding when employing service port735. For example, the mechanical features of secondary access715may first ground a battery chassis before making electrical contact with any power conductors.

Some embodiments include special interface requirements for service port735and/or secondary access715. These requirements are intended to prevent or limit access to battery pack104using service port735. Some of these requirements may include installation of secondary access715at a hidden location in the operating environment to thus secure access to secondary access715so that is may be accessed only by use of a special tool. Some embodiments include use of an electro-mechanical interface with different plug/receptacle form factors from those used with primary access710.

Some embodiments include use of a tamper evident technology to secure service port735and limit use. One such implementation may include installation of a tamper evident label securing secondary power connector and preventing use unless the label is removed. The label providing suitable warnings, use instructions, and in some cases, identification of an access protocol to limit negative consequences of accessing battery pack104through service port735.

FIG. 8illustrates a service port access process800. Process800includes steps805-845that may be automated or implemented by a technician, service engineer, or other qualified individual. Process800begins at step805when evaluation of energy management scenario700establishes a desirability of using service port735instead of operational port730. After step805, process800implements step810in which tamper-evident technology is employed to warn against use of service port735in inappropriate ways. For example, a tamper-evident label may be installed on battery pack104, secondary access715, or other interlocking element of operating environment705. The label identifies an access protocol and may include cautions and best practices for use of service port735. Some embodiments include a contact reference (e.g., a phone number, email, web-access, or other methodology) in which authorization (automated or manual) may be obtained.

Process800includes a test at step815as to whether the further actions are consistent with the identified access protocol. When the test at step815is negative then process800branches to step820. Step820includes accessing service port735, such as by removing or otherwise defeating the tamper-evident technology. Process800includes a step825noting that the access at step820was conducted without a record of pre-authorization. This can have consequences, such as voiding a warranty or increasing costs of subsequent servicing.

When the test at step815was affirmative then process800branches to step830. At step830, there is an automated or manual evaluation of the requested access, such as by the manufacturer or authorized representative. After the evaluation of step830then process800includes a test at step835based upon whether access to service port735is granted/authorized. When the test at step835is negative, process800may terminate or return to step805to collect more information or reconsider a desirability of access to service port735.

When the test at step835is affirmative, then process800advances to step840to defeat the tamper-evident technology (e.g., remove the label) and access service port735. Process800includes a step845noting that the access at step840was conducted with a record of pre-authorization. (The authorization recorded at step840such as by providing an access code, associating a service record, or the like.) The pre-authorization eliminates any of the unauthorized consequences referenced herein.

While examples and implementations have been described, they should not serve to limit any aspect of the present invention. Accordingly, implementations of the invention can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations thereof. Apparatus of the invention can be implemented in a computer program product tangibly embodied in a machine readable storage device for execution by a programmable processor; and method steps of the invention can be performed by a programmable processor executing a program of instructions to perform functions of the invention by operating on input data and generating output. The invention can be implemented advantageously in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and at least one output device. Each computer program can be implemented in a high level procedural or object oriented programming language, or in assembly or machine language if desired; and in any case, the language can be a compiled or interpreted language. Suitable processors include, by way of example, both general and special purpose microprocessors. Generally, a processor will receive instructions and data from a read only memory and/or a random access memory. Generally, a computer will include one or more mass storage devices for storing data files; such devices include magnetic disks, such as internal hard disks and removable disks; magneto optical disks; and optical disks. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto optical disks; and CD ROM disks. Any of the foregoing can be supplemented by, or incorporated in, ASICs.

The system and methods above has been described in general terms as an aid to understanding details of preferred embodiments of the present invention. In the description herein, numerous specific details are provided, such as examples of components and/or methods, to provide a thorough understanding of embodiments of the present invention. Some features and benefits of the present invention are realized in such modes and are not required in every case. One skilled in the relevant art will recognize, however, that an embodiment of the invention can be practiced without one or more of the specific details, or with other apparatus, systems, assemblies, methods, components, materials, parts, and/or the like. In other instances, well-known structures, materials, or operations are not specifically shown or described in detail to avoid obscuring aspects of embodiments of the present invention.