Patent Publication Number: US-2023138106-A1

Title: Containerized battery system and anti-condensation control system for same

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to a containerized battery system, and more particularly to controlling access to a containerized battery system to limit condensation on batteries and related components. 
     BACKGROUND 
     Containerized power modules are increasingly in use throughout the world. Providing power generation and power storage equipment in a containerized form offers many advantages respecting availability of electrical power for primary as well as backup power requirements at construction sites, industrial and data center facilities, and at a great many other locations such as mine or well sites, disaster zones, hospitals, et cetera. 
     In a typical containerized battery system electrical batteries are stored within a container such as an ISO (International Organization For Standardization) container. Many such containers can be readily transported on a truck, by rail, or on a marine vessel. In most applications, such containerized systems can be readily dispatched, redeployed, and serviced in the field. 
     Many modern electrical batteries, notably lithium-ion batteries, are optimally maintained in a relatively tight temperature range of 20° to 30° C. to extract better cycle performance and to minimize degradation of the batteries over time. For inspection and maintenance purposes, doors are typically installed on the containers where personnel may enter to service batteries or other equipment. In certain climates, particularly relatively hot and humid climates, when the service doors are opened humid air can enter the container with water condensing on the surface of the batteries and other electrical components given that the batteries are maintained at temperatures often colder than ambient. This can lead to performance degradation or failure of the system due to short circuits, and potentially cause other problems. One known power generation system is set forth in U.S. Pat. No. 7,221,061. In the &#39;061 patent a containerized power generation system employs an engine having an external process module. 
     SUMMARY 
     In one aspect, a containerized battery system includes a container having a container door, and batteries within the container, and an electronically controlled container heater. The system further includes an anti-condensation control system having inside sensors structured to monitor a temperature and a humidity inside the container, outside sensors structured to monitor a temperature and a humidity outside the container, a door access device adjustable among a plurality of states including an unrestricted-access state and a restricted-access state, and an access control unit. The access control unit is coupled with each of the electronically controlled container heater, the inside sensors, the outside sensors, and the door access device. The access control unit is structured to determine an inside dewpoint value based on the monitored temperature and humidity inside the container, and to determine an outside dewpoint value based on the monitored temperature and humidity outside the container. The access control unit is further structured to operate the electronically controlled heater to increase an inside temperature of a container to an anti-condensation target temperature based on a difference between the inside dewpoint value and the outside dewpoint value. The containerized battery system is further structured to adjust the door access device to the unrestricted-access state based on the increase to the inside temperature of the container. 
     In another aspect, a method of operating a containerized battery system includes receiving a user access request to open a door to a container having batteries therein, and determining an inside dewpoint value of the container and determining an outside dewpoint value, responsive to the user access request. The method further includes comparing the inside dewpoint value to the outside dewpoint value, and increasing an inside temperature of the container from a working temperature to an anti-condensation target temperature based on a difference between the inside dewpoint value and the outside dewpoint value. The method still further includes enabling access to the container via the door based on the increase in the inside temperature to the anti-condensation target temperature. 
     In still another aspect, an anti-condensation control system for a containerized battery system includes a door access device adjustable among a plurality of states including an unrestricted-access state and a restricted-access state. The control system further includes an access control unit coupled with the door access device and structured to receive a user access request produced by the door access device, receive data indicative of an inside dewpoint temperature of a container, and receive data indicative of an outside dewpoint temperature. The access control unit is further structured to compare the inside dewpoint temperature to the outside dewpoint temperature, and adjust the door access device from the unrestricted-access state to the restricted-access state based on the user access request. The access control unit is still further structured to output a heater control signal to an electronically controlled container heater to increase an inside temperature of the container from a working temperature to an anti-condensation target temperature that is greater than the outside dewpoint temperature. The access control unit is still further structured to adjust the door access device from the restricted-access state to the unrestricted-access state based on the increase to the inside temperature of the container. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a diagrammatic view of a containerized battery system, according to one embodiment; 
         FIG.  2    is a schematic view of a containerized battery system, according to one embodiment; and 
         FIG.  3    is a flowchart illustrating example methodology and logic flow, according to one embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG.  1   , there is shown a containerized battery system  10 , according to one embodiment. Battery system  10  includes a container  12  having at least one container door  14  that provides access for personnel inside container  12 . Container  12  is also equipped with a latching/locking mechanism  16  that can include a known handle and manually or electronically operable lock (not shown) to secure container door  14 . Battery system  10  is also equipped with a shore power connection  18  enabling apparatus inside container  12  to be electrically connected to a local electrical grid, to any electrical grid, or directly to a load, to receive electrical power for charging batteries within container  12 , or to discharge batteries within container  12  to provide electrical power, as the case may be. Apparatus inside container  12  can be electrically powered via shore power when battery system  10  is serviced. Container  12  can include a known container configuration, for example, having any of a range of ISO footprints enabling container  12  and battery system  10  to be transported by truck, rail, or marine vessel, and handled with a variety of types of standard ISO container handling equipment. Battery system  10  can be situated at a construction site, a data center or server farm, at a wellhead, a mine, at an industrial location, as well as at virtually every other conceivable location including disaster sites. As explained above, containerized battery systems can be deployed at relatively hot and humid locations. Batteries to be described in battery system  10  are often operated in a working temperature range that is, at least at times, cooler than an ambient temperature. Depending upon dewpoint levels inside container  12 , and outside container  12  when container door  14  is opened batteries inside container  12  can be exposed to air having a dewpoint greater than a battery module or battery pack temperature or another temperature inside container  12 , resulting in condensation depositing upon the equipment. As will be further apparent from the following description, battery system  10  is equipped with control system and logic functions that enable increasing an inside temperature of container  12  above an outside dewpoint temperature to limit or eliminate any condensation that might otherwise occur. 
     Referring also now to  FIG.  2   , battery system  10  further includes batteries  22  within container  12 , such as lithium-ion batteries, supported on or by battery racks  24 . Battery system  10  also includes an HVAC system  20  having an electronically controlled container heater  26  and an electronically controlled container cooler  28 . Battery system  10  further includes an anti-condensation control system  30 . Control system  30  may include inside sensors structured to monitor a temperature and humidity inside container  12 , including for instance one or more inside temperature sensors  32  and an inside humidity sensor  34 . The one or more inside temperature sensors  32  may include battery module or battery pack temperature sensors in contact with or in proximity to one or more of batteries  22 . Inside temperature sensors  32 , hereinafter referred to at times in the singular, together with inside humidity sensor  34 , may be structured to produce temperature data and humidity data indicative of an inside dewpoint value of container  12 . The inside dewpoint value may include an inside dewpoint temperature, but could include a temperature range or zone, or some other numerical value. The outside sensors may include an outside temperature sensor  36  and an outside humidity sensor  38  structured to monitor a temperature and a humidity outside container  12 , namely, an ambient temperature and an ambient humidity, and together structured to produce temperature data and humidity data indicative of an outside dewpoint value such as an outside dewpoint temperature. In other instances, outside temperature data and outside humidity data, or an outside dewpoint value, could be obtained by way of apparatus separate from battery system  10  itself, such as temperature and/or humidity sensors located amongst a plurality of battery systems and indicating the desired information at a location more generally. Combined temperature and humidity sensors are well known and commercially available. 
     Control system  30  may further include a door access device  40  adjustable among a plurality of states including an unrestricted-access state and a restricted-access state. The door access device can include a device that prevents physical opening of container door  14 , such as an electronically controlled lock. In a practical implementation, door access device  40  may perform an access control function without physically locking or unlocking container door  14 . In one embodiment, door access device  40  includes an illuminable indicator and the unrestricted-access state and the restricted-access state include a first illumination state meaning access is allowed and a second illumination state meaning access is not allowed, respectively. For instance, door access device  40  may include a light  41  that is turned on, turned off, varied in intensity or color of illumination, or varied amongst a flashing mode, a non-flashing mode, or still others, as further described herein. 
     Control system  30  further includes an access control unit  50 . Access control unit  50  may be in control communication with container heater  26  and container cooler  28  to send control signals to either and structured to receive a user access request produced by door access device  40 . Access control unit  50  may also be structured to receive temperature data and humidity data (a temperature signal, a humidity signal, or a dewpoint temperature signal, for instance) indicative of an inside dewpoint value, such as a dewpoint temperature, of container  12 , and to receive temperature data and humidity data indicative of an outside dewpoint value, such as a dewpoint temperature. Access control unit  50  may also be structured to determine an inside dewpoint value based on the monitored temperature and humidity inside container  12 , and to determine an outside dewpoint value based on the monitored temperature and humidity outside container  12 . 
     Access control unit  50  may also be structured to compare the inside dewpoint temperature or temperature value to the outside dewpoint temperature or temperature value based on the user access request received. In an implementation, access control unit  50  is structured to adjust door access device  40  from the unrestricted-access state to the restricted-access state based on a difference between the inside dewpoint temperature value or temperature and the outside dewpoint temperature or value. Access control unit  50  may also be structured to output a heater control signal to electronically controlled heater  26 , to increase an inside temperature of container  12  from a working temperature to an anti-condensation target temperature. The anti-condensation target temperature may be greater than the outside dewpoint temperature. Based on the increase to the inside temperature of container  12  access control unit  50  can adjust door access device  40  from the restricted-access state to the unrestricted-access state. This functionality can generally be understood as access control unit  50  varying the state of door access device  40  when a difference between the outside dewpoint temperature and the inside dewpoint temperature is determined, namely, where the inside dewpoint temperature is lower than, or sufficiently lower than, the outside dewpoint temperature, to indicate that a risk of condensation exists. If such risk exists, electronically controlled heater  26  can be operated to increase inside temperature of container  12  to a level sufficient to mitigate the risk of condensation. The anti-condensation target temperature to which the inside temperature of container  12  is increased may be not only greater than the outside dewpoint temperature but also less than or equal to a battery safe temperature. In other words, there may be an upper threshold in temperature above which it is undesirable to heat the inside of container  12 . Access control unit  50  can include a data processor  52 , such as a microprocessor, a microcontroller, or any other suitable programmable logic controller, and a computer readable memory  54 . Computer readable memory  54  can include any suitable memory type such as RAM, ROM, DRAM, SDRAM, EEPROM, FLASH, or still another, and stores program control instructions executed by processor  52  to limit condensation upon batteries  22 , racks  24 , or other equipment inside container  12 . 
     As noted above, door access device  40  can include an illuminable indicator  41 , such as an LED light or the like. Indicator  41  may be an illuminable push-button in some instances functioning as a user access switch structured to produce the user access request. The user access switch and illuminable indicator  41  may be integrated, such that the illuminable indicator  41  is resident on the user access switch. 
     Moreover, once servicing of battery system  10  is complete control system  30  can operate electronically controlled container cooler  28  to decrease the inside temperature of container  12  to a working temperature less than an outside dewpoint temperature, thus after the operating of electronically controlled heater  26  to increase the inside temperature to the anti-condensation target temperature. In an embodiment, access control unit  50  way receive an access completed signal, such as from door access device  40  or another device indicating container door  40  has been closed, for example, and that personnel have exited after completing servicing, and conditions are appropriate for returning container  12  to a standard working temperature. During servicing battery system  10  power can be provided by way of shore power connection  18 . 
     INDUSTRIAL APPLICABILITY 
     With continued reference to the drawings, but also now to  FIG.  3   , there is shown a flowchart  100  illustrating example process and logic flow, according to one embodiment. At a block  105 , a door button (door access device  40 ) is pressed to produce the user access request. Pressing the door button can be understood as a request by personnel to access container  12  by opening door  14 . Responsive to the user access request, at a block  110  an indicator light  41 , such as a light of door access device  40 , may be adjusted from a first illumination state to a second illumination state. In the illustrated block  110  the indicator light is adjusted from red to flashing red. From block  110  flowchart  100  advances to a block  115  to check battery temperature and humidity inside container  12 . Block  115  can be understood as determining an inside dewpoint value of container  12 , for instance via map lookup. From block  115 , or potentially in parallel with block  115 , flowchart  100  advances to a block  120  to check outside temperature and outside humidity, thus determining an outside dewpoint value, again using a map lookup, for example. From block  120  flowchart  100  advances to a block  125  to determine the inside dewpoint value and outside dewpoint value. 
     From block  125  flowchart  100  advances to a block  130  to query are battery temperatures greater than outside dewpoint? Determining whether battery temperatures are greater than the outside dewpoint can include performing an arithmetic comparison and calculating a difference between the respective temperatures, for instance. If yes, flowchart  100  can advance to a block  150  to adjust the indicator light to green to enable container access. 
     If, at block  130 , battery temperatures are not greater than the outside dewpoint, flowchart  100  can advance to a block  140  to operate container heater  26  to increase the inside temperature of container  12  by initiating operating container heater  26  as described herein. From block  140 , flowchart  100  can advance to a block  145  to monitor the inside temperature of container  12  as heater  26  operates. At block  145  access control unit  50  can be monitoring inside temperature in a closed-loop fashion to determine when the anti-condensation target temperature is reached. At a block  150  the indicator light is adjusted to green to enable container access as discussed herein. At a block  155  inside temperature of container  12  is decreased to the working temperature, if needed. At a block  160  the logic exits. 
     The present description is for illustrative purposes only, and should not be construed to narrow the breadth of the present disclosure in any way. Thus, those skilled in the art will appreciate that various modifications might be made to the presently disclosed embodiments without departing from the full and fair scope and spirit of the present disclosure. Other aspects, features and advantages will be apparent upon an examination of the attached drawings and appended claims. As used herein, the articles “a” and “an” are intended to include one or more items, and may be used interchangeably with “one or more.” Where only one item is intended, the term “one” or similar language is used. Also, as used herein, the terms “has,” “have,” “having,” or the like are intended to be open-ended terms. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.