ELECTRIC VEHICLE BATTERY STORAGE VESSEL

An electric vehicle battery transportation storage vessel includes a first housing portion configured to securely receive a storage battery of an electric vehicle, a second housing portion arranged to seal the storage battery in the first housing portion, and selectively open whereby the storage battery can be removed from or placed into the first housing portion. A sealing mechanism is configured to seal the first housing portion to the second housing portion. Battery monitoring equipment is configured to couple to the storage battery and perform battery maintenance on the storage battery. A memory configured to store information related to battery maintenance performed on the storage battery.

BACKGROUND OF THE INVENTION

The present invention relates to electric vehicles of the types which use battery packs for storing electricity. More specifically, the present invention relates to maintenance of such battery packs.

Traditionally, automotive vehicles have used internal combustion engines as their power source. Petroleum as a source of power. However, vehicles which also store energy in batteries are finding widespread use. Such vehicle can provide increased fuel efficiency and can be operated using alternative energy sources.

Some types of electric vehicles are completely powered using electric motors and electricity. Other types of electric vehicles include an internal combustion engine. The internal combustion engine can be used to generate electricity and supplement the power delivered by the electric motor. These types of vehicles are known as “hybrid” electric vehicles.

Operation of an electric vehicle requires a source of electricity. Typically, electric vehicles store electricity in large battery packs which consist of a plurality of batteries. These batteries may be formed by a number of individual cells or may themselves be individual cells depending on the configuration of the battery and battery pack. The packs are typically large and replacement can be expensive.

Electric vehicle batteries and component modules are typically sizable and contain substantial stored electro-chemical energy with lethal voltages present. These two conditions result in significant fire and electrocution potential.

Further, the transportation of these batteries and component modules can create additional safety risk by mishandling, vibration, and impact. Parameters regarding the composition and state of function of these batteries and component modules are frequently regulated by law and means of transport.

Additionally, these assets have significant monetary value; however, if not properly maintained can degrade substantially over time and temperature.

SUMMARY OF THE INVENTION

An electric vehicle battery transportation storage vessel includes a first housing portion configured to securely receive a storage battery of an electric vehicle, a second housing portion arranged to seal the storage battery in the first housing portion, and selectively open whereby the storage battery can be removed from or placed into the first housing portion. A sealing mechanism is configured to seal the first housing portion to the second housing portion. Battery monitoring equipment is configured to couple to the storage battery and perform battery maintenance on the storage battery. A memory configured to store information related to battery maintenance performed on the storage battery.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Embodiments of the present disclosure are described more fully hereinafter with reference to the accompanying drawings. Elements that are identified using the same or similar reference characters refer to the same or similar elements. Some elements may not be shown in each of the figures in order to simplify the illustrations.

The various embodiments of the present disclosure may be embodied in many different forms and should not be construed as limited to the specific embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art.

As discussed in the background section, battery packs used with electric vehicles are able to store large amounts of energy. The battery packs are large and difficult to work on and test because of the high voltages involved. Further, the battery packs are expensive. After removing a storage battery from an electric vehicle, the battery may need to be transported to another location. The transportation process should ensure safety of both the transporting vehicle as well as the battery. Further, it is important to ensure that the battery is maintained during transportation.

In one aspect of the present invention, a battery pack is removed from the electric vehicle whereby maintenance can be performed on it. In many instances, the maintenance needs to be performed at a different location and the storage battery must be transported to that location. In one aspect, the present invention provides an electric vehicle battery storage vessel which can receive different configurations of storage batteries, secure the storage battery and/or provide maintenance to the storage battery while the battery is in the vessel.

FIG.1is a simplified block diagram of an electric vehicle100. Electric vehicle100can be configured to operate solely based upon electric power, or may include an internal combustion engine. Vehicle100includes a battery pack102and at least one electric motor104. Vehicle electronics and control system106couples to the battery pack and electric motor and is configured to control their operation. Wheels110of vehicle100are configured to propel the vehicle in response to a mechanical input from electric motor104. Electric motor104operates using energy drawn from the battery102. In some configurations a regenerative braking system can be used in which a braking energy is recovered from the wheels110by the electric motor104or other equipment. The recovered energy can be used to recharge the battery pack102.

FIG.1also shows optional components of vehicle100. These optional components allow the vehicle100to operate as “hybrid” vehicle. In such a configuration, an internal combustion engine120is provided which operates using, for example, petroleum-based fuel122. The engine120can be configured to directly mechanically drive the wheels110and/or an electric generator122. The electric generator122can be configured to charge the battery pack102and/or provide electrical power directly to electric motor104.

The battery pack102is a critical component of the electric vehicle100. Operation of the battery pack102will determine the efficiency of the vehicle, the overall range of the vehicle, the rate at which the battery pack102can be charged and the rate at which the battery pack102can be discharged.

FIG.2is a simplified diagram of an example configuration of battery pack102. InFIG.2, a plurality of individual batteries140are shown connected in series and parallel. Each of the individual batteries140may comprise a single cell or may comprise multiple cells connected in series and/or parallel. These may be removable battery modules formed by a single cell or a group of cells. If elements140are a group of cells, in some configurations individual connections may be available within the battery and used in accordance with the invention.

During the lifetime of vehicle100, the battery pack102will degrade with time and use. This degradation may be gradual, or may occur rapidly based upon a failure of a component within the pack102. When such a failure occurs, or when the pack has degraded sufficiently, the entire battery pack102is typically replaced. The battery pack102is one of the primary components of electric vehicle100and its replacement can be very expensive. In one aspect, the present invention is directed to performing maintenance on battery pack102. The maintenance can be performed after the battery pack has failed, or prior to the failure of the battery pack. The maintenance can include placement in a battery storage vessel for transport to another location

During operation, device200is capable of measuring a parameter of battery140through the Kelvin connections206and208. For example, a forcing function can be applied by forcing function210. Measurement circuitry212can monitor the effect of the applied forcing function signal on the battery140and responsively provide an output to microprocessor214. This can be used to measure a dynamic parameter of the battery such as dynamic conductance, etc. The present invention is not limited to this particular testing method and other techniques may also be employed. Further, the testing of battery140or group of batteries140may be performed using sensors within battery pack102. In such a configuration, the testing may be performed without disassembling the battery pack102. Microprocessor214can operate in accordance with programming instructions stored in memory220. Memory220can also store information by microprocessor214. Operation of device200can be controlled by user I/O220which can comprise, for example, a manual input such as a keyboard and/or an output such as a display. As discussed below in greater detail, measured parameters of battery can be stored in database222for subsequent retrieval.

FIG.4shows an example configuration of database222. Database222includes a number of different fields. A battery identification field224is used to store information which identifies a battery140. The battery140may be a battery from within an existing battery pack102or may be a new battery140. At least one battery parameter226is associated with an identified battery which is collected by maintenance device200. In some configurations, more than one battery parameter226is associated with one specific battery140.

The battery identification224can be in accordance with any technique which will provide information which can be used to identify a battery. This may include, for example, a serial number or the like. The identifying information can be created during the refurbishing process, or at some other time, for example, during manufacture of a battery140or pack102. This information may be manually entered into the database222using, for example, user I/O220shown inFIG.3or may be entered into database222using more automated techniques such as a barcode scanner, RFID tag, etc. User I/O220may comprise such inputs. The battery parameter226can comprise any information which is related to an identified battery140. The information can be information obtained through a battery test or may be information obtained through other means. For example, information related to the age of the battery may be used, information related to whether the battery140came from a battery pack102in which an operator has or has not identified any problems, manufacturing information, geographic location information, information related to a location of a battery within the battery pack102, etc. Examples of other parameters include parameters collected by testing the battery may include temperature, etc. The temperature may be, for example, a temperature profile obtained during transportation or otherwise while the battery is contained in the storage vessel198. These parameters may include the results of any type of battery test or data measured or collected prior to, during, or after a test is performed and are not limited to those discussed herein.

During operation of the system discussed above, any bad battery packs102are identified by testing. This may require that the battery pack102be charged and discharged. Further, battery pack102may be charged or discharged while on vessel198.

Industrial batteries may be tested while remaining in the pack through connections at individual points between multiple batteries. In another example, the entire battery pack102may be tested by supplying a known current to the entire pack102, or a portion of the pack102. This current may be a DC current, a time varying DC current, a bi-polar current, a uni-polar AC current, etc. While is current is applied, a battery140or groups of batteries140within the battery pack102or the entire pack can be monitored. This monitoring may be through sensors which are internal to the battery pack102or through sensors which are separably applied to the battery pack102.

FIG.5is a simplified block diagram of vessel198showing battery tester200including a battery cradle350. Tester200includes test circuitry352coupled to user I/O220.FIG.7also illustrates a remote I/O connection354for communicating with a remote location such as over a network, to a centralized data system, to other electrical equipment, to a remote user, etc. An optional printer356is also illustrated inFIG.5and can be used to provide a physical hard copy of test results or other information.

The test circuitry352couples to the cradle350through cable360. Cable360has ends362and364which plug into the battery cradle350and the test circuitry352, respectively. The battery140can be placed into the cradle350whereby tests may be performed on the battery140. Battery140is illustrated as including battery terminals202and204which couple to Kelvin connections206and208in cradle350. These may be Kelvin connections or single connections. A midpoint connector370is also illustrated which allows a midpoint test connector372to connect to one or more connections between cells or groups of cells within the battery140. The cradle350may also be configured to accept an entire battery pack104.

The configuration shown inFIG.5simplifies the technical requirements of connecting a battery to the battery test circuitry. The use of an individual cradle allows the battery to simply be “snapped” into place for maintenance and transportation. Further, the cradle350is configured to provide typical stability to the battery140and secure the battery140in storage vessel198during transportation. Additionally, the cradle350can include shock absorbing material and other shock absorbing configuration in which shocks experienced during transportation are reduced. The cradle can include a protective case cover and integrated safety lock to protect the operator and circuitry during testing. Mechanical and/or electrical polarity detection can be used as discussed below in greater detail. The cable360can be replaceable as if it becomes worn through extended use. Additionally, different types of cradles can be used for different types of batteries140and simply plugged into the cable360. Some particular types of cradles350may use different types of cabling connections360. This allows the particular cable to be easily exchanged and/or plugged into a different type of cradle350. In one configuration, the cable360represents a wireless communication link such as an RF link using BlueTooth®, WIFI, etc. In such a configuration, part of the test circuitry maybe located within the cradle350in order to sense voltages directed and/or apply forcing functions. The remote I/O354can then communicate as appropriate including wireless or wired connections such as Ethernet, WIFI, etc. The battery test circuitry352can be configured for testing, discharging and charging the battery140. Some tests or battery maintenance may require discharging or recharging as well as testing the battery140.FIG.5also illustrates an optional sensor351. Sensor351may be a single sensor or a plurality of sensors located either internally and/or externally with respect to the storage vessel198. Example sensors include temperature sensors, gas sensors, motion sensors, geo positioning sensors or location sensors, shock sensors, altitude sensors, moisture sensors, optional sensors, acoustic sensors, pressure or weight sensors. The measurements obtained by sensor351can be used in the battery test, for example adjusting various test parameters, etc. Additionally, the sensor output information can be stored in memory220, database222so it is logged for future reference and/or transmitted to a remote location. This can also be used to determine if a storage battery has been exposed to an improper environment during transportation which may have caused damage to the storage battery. These are examples of environmental sensors and the sensed environment may be an environment internal to the storage vessel198and/or external to the storage vessel198.

In some configurations, the cradle350can be configured to accept multiple types of individual batteries140or battery packs104. This allows a single storage vessel198to be used with multiple different types of batteries and battery packs. In another configuration, the cradle350is removeable from the storage vessel198whereby a cradle350can be selected for a specific or unique type of battery140or battery pack104. This allows the same battery storage vessel198to be used with a wide array of different types of batteries and battery packs.

In one configuration, the state of charge of the battery may be determined using an approximate relationship between voltage of the battery, and/or current in/out of the battery, and state of charge. Other techniques may be used including measurement of dynamic parameter as discussed above. When charging a battery, the battery can be charged using a constant current or constant voltage mode as desired. In such embodiments, the forcing function210is configured as a constant or variable current source, a constant or variable voltage source, as well as a load including a constant or variable current load.

Preferably, the test circuitry includes a fail-safe configuration whereby if a voltage of a battery is out of a predetermined range, such as 2.5 volts to 4.25 volts, the current or voltage applied to the battery140may be terminated. A power on self test (POST) and/or watchdog timer can be selectively provided within test circuitry252in order to improve the reliability of the device. In one configuration, a “start” button is provided on the user I/O220which can be used to initiate a maintenance cycle. Over voltage, current and temperature protection is preferably provided in order to protect the battery and the maintenance circuitry.

FIG.6shows graphs of battery voltage and battery current during a constant voltage charging mode. As illustrated inFIG.7, during a first phase of operation, a constant current is applied to the battery. In a second period, a constant voltage is applied to the battery followed by a waiting time. These periods can be cycled in order to maximize battery charge. Similarly,FIG.7shows a constant current discharging mode. In such a configuration a constant is applied to the battery for a first period of time. The discharge current is then brought to zero amps.

FIG.8is a perspective view of electric vehicle battery storage vessel198.FIGS.8-28illustrate specific examples of various aspects of the present invention. As illustrated inFIG.8, vessel198includes a lower or first housing portion400which is configured to receive the storage battery of electrical vehicle along with an upper or second housing portion200. In the specific illustrated configuration, housing portions400and402are secured together using releasable latches. An optional hinge may also be used between the two housing portions400and402. The latch404is more clearly illustrated inFIG.9. As illustrated inFIG.10, an optional outgassing vent410may be provided on one of the housing portions to allow for the escape of gas from within the sealed vessel198. For example, a battery may experience outgassing resulting in significant pressure build up within the vessel198.

FIG.11is a view of an interior of portion400configured to receive the storage battery or battery cradle. A shock absorbing footing412is illustrated which reduces shock and impact vibrations from being transmitted to the stored storage battery.FIG.12illustrates latch404in a released position allowing separation of portions400and402.FIG.13shows an integrated lifting connection420. The lifting connection420can be located on an interior of the vessel128, for example in portion400, or can be located on an exterior surface. Portion402can include a groove422as illustrated inFIG.14. This groove422can be configured to receive feet424shown inFIG.8and inFIG.15. The configuration of groove422and feet424allows the units to be backed and nested together as illustrated inFIG.20. Optional safety markers430as illustrated inFIG.16can be included on an exterior surface of vessel198.

An option documentation pouch is illustrated inFIG.17. Pouch432can be used to carry paperwork associated with a storage battery carried within the electric vehicle battery storage vessel198.

In one aspect, fire suppression equipment is included within the vessel198. For example, a heat activated fire extinguisher440as illustrated inFIG.18can be placed in portion400of vessel198. Additionally, the fire suppressing device can be activated manually. The device440can be triggered by the temperature within the vessel198exceeding a temperature threshold. Further, an electrical plug442can be provided which includes electrical connections which extend from an exterior of vessel198to an interior of vessel198as illustrated inFIG.19. This can be used to provide connections to battery140for charging or discharging. In another configuration this provides connections to, for example, test circuitry352shown inFIG.5. For example, for user I/O220, remote I/O354, printer356, etc. A display450can also be provided on an exterior surface of vessel198as shown inFIG.21. For example, this can be user I/O220illustrated inFIG.5. This can display information regarding the vessel198itself or battery140carried within the vessel198. This can also be used to provide test results, state of charge information, etc. In one configuration element450also includes a user input whereby an operator can control the maintenance of battery140for example initiating a test, initiating charging, initiating discharging, etc. A gas sensor452as illustrated inFIG.22can also be provided to sense the presence of gas due to any outgassing from battery140. This can activate an alarm or provide some other output to alert an operator as to the condition of the battery140within the vessel198. Another example of a sensor carried on vessel198is a shock sensor454as illustrated inFIG.23.

FIG.24illustrates a DC to DC converter460. This can be used to power the battery monitoring electronics from energy contained in the storage battery itself. An optional geotag464is shown inFIG.25which can record the location of the vessel198for example using GPS coordination. This can also be configured to transmit the location information to another location whereby the vessel198can be tracked as it transports a battery between locations. Another example of an operator or user output is a warning light or warning alarm466illustrated inFIG.26. This can be activated based upon a test performed on the storage battery, a measurement taken of the ambient environment or environment within the storage vessel198, or through some other means. This allows an operator to identify a particular storage vessel198. For example, if an operator wishes to retrieve a particular storage battery, the storage vessel198can be contacted remotely to active indicator466whereby the operator can identify that vessel198.

The various concepts and features set forth above can be used to implement the vessel of the present invention.

Features of the enclosed vessel include: fire resistant reusable shell, optionally explosion proof, sealed construction with or without gas release safety vent, shock mounting mechanism for battery pack or component modules, quick release straps or clamps, integral lifting apparatus for battery placement and removal, nested design for stacking enclosures safely, forklift channels integral to the enclosure, standardized safety markings and colors, document pocket for contents specifics, built-in Fire suppression-auto activated or manually activated, connection for charging or discharging while the module or pack is in the enclosure, stackable for easier warehouse or service garage storage, real time wired/wireless connection for alerts or contents status (safety or otherwise) and eternal status indicator for warnings connected to sensor (wired or wireless).

Example sensor features include: low power system for continuous operation powered by primary or secondary cells, gas sensor to detect presence of toxic or explosive gases contained within the vessel, shock sensor to capture potential transportation damage, DC/DC converter to power monitor system from battery or component modules directly, capability to query built in battery or module monitor electronics to read cell, module or pack voltages and temperatures, capability to close battery contactors to read voltage, integral GPS sensor for asset tracking or geo-fencing, serialized enclosure tracking number and can be programmed to check that pack meets all shipping requirements before assigned to container and generating a unique code to verify the pack is safe to ship.

Reporting features include: reporting methods for all sensors, panel display reading out conditions within the enclosure, wireless connections for transmission of conditions to portable readers or cloud connectivity. This includes communication with personal electronic devices, such as cell phones and apps to enable such communication, remote monitoring using app or cloud based solution, warning lights for conditions requiring attention, buzzer for conditions requiring attention, green light to indicate safe to transport, indication of safe for air shipment (SOC below 30%), green light to indicate OK to store, readout of battery voltage or state of charge, readout of internal temperature, flip sign to show current status of enclosed battery similar to type used on freight trailers, tailored to appropriate battery messages and ability to tie serial number from transport container to batter serial number and create unique shipping code.

Maintenance features include: capability to discharge within the enclosure, capability to discharge with connected external equipment, capability to recharge within the enclosure, capability to recharge with connected external equipment and ability to set contactors to open positions.