DESC:SYSTEM TO MANAGE AND MONITOR SWAPPABLE BATTERY PACKS
CROSS REFERENCE TO RELATED APPLICTIONS
The present application claims priority from Indian Provisional Patent Application No. 202421001200 filed on 06-01-2024, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to energy management systems. Further, the present disclosure particularly relates to a system to manage and monitor the swappable battery packs.
BACKGROUND
Swappable battery packs have become an important aspect of energy management in applications such as electric vehicles, energy storage systems, and uninterrupted power supplies. Over time, batteries utilized in electric vehicles undergo performance degradation due to repeated charge-discharge cycles, thermal variations, and aging processes. Once degraded, such batteries are often recycled or discarded, which results in a premature end to the useful life of the resource and contributes to environmental challenges.
Degraded batteries, despite a reduction in performance, retain significant capacity to meet energy requirements for applications that operate under lower power demand. Examples of such applications include energy storage systems for renewable energy, battery swapping stations, domestic uninterrupted power supplies, and commercial backup systems. The repurposing of degraded batteries for the secondary uses offers an opportunity to extend the operational lifespan of such batteries while addressing waste management concerns.
Existing systems for managing battery packs primarily focus on their use in primary applications, such as mobility solutions, without considering the potential for repurposing degraded batteries. Such systems often lack mechanisms to monitor and analyse parameters that determine the suitability of batteries for secondary use. Additionally, conventional server arrangements and monitoring systems do not provide the necessary analytics to classify degraded batteries or allocate them for alternate applications based on their remaining capacity and safety characteristics.
The absence of a framework to assess, categorize, and reallocate degraded batteries results in missed opportunities to optimize the lifecycle of battery resources. For example, a battery with a moderate reduction in capacity could serve as a reliable energy storage unit in a solar panel system, while another with significant degradation might still function as a backup power source for low-demand applications. Without the ability to predict remaining operational life and determine appropriate use cases, the management of degraded batteries remains inefficient.
In view of these challenges, there exists a need for a system that integrates the management and monitoring of swappable battery packs with the ability to evaluate degraded batteries for secondary applications. Such a system would facilitate sustainable utilization by extending the lifecycle of batteries and reducing environmental impacts associated with premature recycling or disposal.
SUMMARY
The aim of the present disclosure is to provide a system to manage and monitor the swappable battery packs to evaluate degraded batteries for secondary applications.
The present disclosure relates to a system to manage and monitor swappable battery packs. The system comprises swappable battery packs, wherein each swappable battery pack is associated with a battery management unit to monitor health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters. The system further comprises a server arrangement communicably coupled with each swappable battery pack. The server arrangement acquires monitored health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters from each swappable battery pack. The server arrangement analyses such parameters to determine an application domain for each battery, wherein the application domain is selected from mobility solutions, energy storage solutions, battery swapping stations, domestic uninterrupted power supplies, and commercial uninterrupted power supplies.
In another aspect, the present disclosure provides a method for managing and monitoring swappable battery packs. The method comprises monitoring health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters of each swappable battery pack through a battery management unit. The method further comprises communicably coupling a server arrangement with each swappable battery pack, acquiring monitored parameters from each swappable battery pack, and analysing such parameters to determine an application domain for each battery, wherein the application domain is selected from mobility solutions, energy storage solutions, battery swapping stations, domestic uninterrupted power supplies, and commercial uninterrupted power supplies.
The method further comprises assigning priority levels to each swappable battery pack. The priority levels are based on health parameters and safety parameters, enabling optimized allocation of batteries for specific applications according to their operational status and safety considerations.
The method further comprises recalibrating received electrical parameters, thermal parameters, and safety parameters. The recalibration is based on weather data, assuring that the system dynamically adapts to changing environmental conditions to maintain optimal performance and safety of the batteries.
The method further comprises determining an adaptive charging policy. The adaptive charging policy is established for each swappable battery pack based on analysed parameters. Such a policy optimizes charging patterns to balance energy delivery, safety, and battery longevity.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 illustrates a system to manage and monitor the swappable battery packs, in accordance with the embodiments of the present disclosure.
FIG. 2 illustrates a method for managing and monitoring swappable battery packs, in accordance with the embodiments of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a motor of an electric vehicle and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings, and which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the term "swappable battery pack" refers to an energy storage unit that is removable and replaceable within a system. Said swappable battery pack stores electrical energy and supplies the stored electrical energy to connected systems or devices. The structure of the swappable battery pack may comprise one or more electrochemical cells encased in a protective housing, with electrical connectors and safety components. The electrochemical cells may be of various types, such as lithium-ion, nickel-metal hydride, or lead-acid, selected based on performance requirements, cost, and lifespan. Swappable battery packs may be utilized in electric vehicles, renewable energy storage, and backup power supply systems. Examples of connectors comprise Anderson-type connectors and spring-loaded contacts for safe and efficient power transfer. Safety components may comprise fuses, thermal cutoffs, and overcurrent protection circuits to enable proper operation and prevent hazardous conditions such as overheating or overcharging.
As used herein, the term "battery management unit" refers to an electronic system associated with a swappable battery pack to monitor, regulate, and control the performance. Such a battery management unit measures key parameters, comprising voltage, current, temperature, state of charge, and state of health. The battery management unit further assures balance among individual cells by incorporating balancing circuits, such as resistive or active balancing circuits. Examples of monitoring components comprise thermistors for temperature sensing, shunt resistors for current measurement, and voltage dividers for voltage measurement. The battery management unit performs safety checks by detecting conditions such as overvoltage, undervoltage, or thermal anomalies.
As used herein, the term "server arrangement" refers to a computing system communicably coupled with each swappable battery pack to process and store data. Such a server arrangement comprises components such as processors, memory devices, and network interfaces. Communication between the server arrangement and swappable battery packs may occur over wired or wireless networks, utilizing communication standards such as Bluetooth, Wi-Fi, or cellular networks. The server arrangement acquires monitored data, comprising health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters, from each swappable battery pack.
As used herein, the term "health parameters" refers to metrics that assess the operational condition of a battery pack. Such parameters comprise state of health, capacity retention, and internal resistance. State of health represents the ratio of the current capacity to the original capacity of the battery, while internal resistance refers to the resistance encountered by the current flowing through the battery cells. Measurement of such health parameters may involve techniques such as impedance spectroscopy or coulomb counting.
As used herein, the term "usage parameters" refers to data representing the operational history and usage patterns of a battery pack. Such parameters comprise the total number of charge-discharge cycles, average depth of discharge, and operational time at different load conditions. Usage parameters are recorded by the battery management unit and relayed to the server arrangement for analysis.
As used herein, the term "electrical parameters" refers to measurable characteristics of a battery pack that define the electrical performance. Such parameters comprise voltage, current, and power output. Voltage refers to the potential difference across the battery terminals, while current represents the rate of charge flow. Power output is calculated as the product of voltage and current. Measurement of electrical parameters involves devices such as voltage sensors, current sensors, and wattmeter. For instance, a battery pack with a nominal voltage of 48V and a maximum current of 100A is suitable for medium-duty applications such as electric scooters or small backup systems.
As used herein, the term "thermal parameters" refers to temperature-related metrics of a battery pack that influence the safety and performance. Thermal parameters comprise surface temperature, internal temperature of cells, and ambient temperature. Measurement devices for thermal parameters comprise thermocouples, infrared sensors, and temperature-sensitive resistors. For example, a temperature sensor embedded in the battery management unit may detect heat/thermal profile of battery pack.
As used herein, the term "safety parameters" refers to indicators that monitor the safety status of a battery pack during operation. Such parameters comprise overcurrent thresholds, short-circuit detection, and thermal runaway conditions. Monitoring safety parameters involves sensors and protection mechanisms integrated into the battery management unit.
As used herein, the term "adaptive charging policy" refers to a dynamic set of charging guidelines tailored to optimize the performance and longevity of a battery pack. Such a policy adjusts charging rates, voltage thresholds, and current limits based on real-time conditions and historical data.
As used herein, the term "alert" refers to a notification (e.g., SMS, email, push notification etc.) generated by the system to warn of risks or operational anomalies in a battery pack. Alerts may be issued in the form of visual signals, auditory warnings, or digital messages.
FIG. 1 illustrates a system 100 to manage and monitor the swappable battery packs, in accordance with the embodiments of the present disclosure. The system 100 comprises swappable battery packs 102, wherein each swappable battery pack 102 is a portable energy storage unit capable of being removed and replaced within a system. Each swappable battery pack 102 comprises a housing enclosing electrochemical cell, such as lithium-ion, nickel-metal hydride, or lead-acid cells, arranged in series or parallel configurations to achieve the desired voltage and capacity. Each swappable battery pack 102 comprises electrical connectors for interfacing with external systems, as well as safety mechanisms, such as overcurrent protection, thermal cutoffs, and insulation layers, to prevent operational hazards such as overheating, short circuits, or overcharging. The swappable feature of the battery packs 102 enables rapid exchange, allowing depleted battery packs 102 to be replaced with fully charged units, minimizing system downtime. Each swappable battery pack 102 can be utilized across various application domains, comprising but not limited to mobility solutions, such as electric vehicles, energy storage systems, domestic and commercial uninterrupted power supply systems, and battery swapping stations.
In an embodiment, each swappable battery pack 102 is associated with a battery management unit 104, which monitors health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters of the battery pack 102. The battery management unit 104 tracks the state of charge, state of health, and cycle count, while also monitoring conditions such as voltage, current, temperature, and internal resistance. Monitoring methods comprise the use of thermistors, voltage dividers, and current sensors integrated within the battery management unit 104. The battery management unit 104 also comprises balancing circuits, such as resistive or active balancing circuits, to equalize the charge among cells in the battery pack 102. Additionally, the battery management unit 104 performs safety checks by detecting overvoltage, undervoltage, overcurrent, and thermal anomalies, and triggers protective actions to prevent unsafe conditions. The battery management unit 104 further records usage parameters, such as the total number of charge-discharge cycles and average depth of discharge and stores such data for subsequent analysis or transfer to external systems. Data collected by the battery management unit 104 is important for evaluating the performance and operational status of the swappable battery packs 102, enabling informed decision-making regarding their utilization and maintenance.
In an embodiment, the system 100 further comprises a server arrangement 106 communicably coupled with each swappable battery pack 102. The server arrangement 106 establishes communication links with the battery management unit 104 of each swappable battery pack 102 via wired or wireless methods, such as Bluetooth, Wi-Fi, or cellular networks. The server arrangement 106 acquires monitored data, comprising health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters, from each swappable battery pack 102. The acquired data is stored and processed within the server arrangement 106 to facilitate analytics and decision-making. The communication infrastructure of the server arrangement 106 enables integration with multiple swappable battery packs 102, allowing for centralized monitoring and management. The server arrangement 106 may comprise hardware components such as processors, memory units, and network interfaces, as well as software components that perform data processing and storage functions.
In an embodiment, the server arrangement 106 analyses the acquired health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters to determine an application domain for each swappable battery pack 102. The analysis involves evaluating the current state of charge, state of health, and remaining capacity of each swappable battery pack 102 to assess the suitability for various applications. Application domains comprise mobility solutions, such as electric vehicles, which require high-capacity and high-performance batteries; energy storage systems, which prioritize stable and consistent energy output; battery swapping stations, which demand fast replacement and recharging capabilities; domestic uninterrupted power supply systems, which require moderate energy capacity for household devices; and commercial uninterrupted power supply systems, which cater to higher energy demands in commercial facilities. The analysis performed by the server arrangement 106 enables the allocation of swappable battery packs 102 to the most appropriate application domain based on their performance metrics and operational requirements.
In an embodiment, the server arrangement 106 may generate a maintenance schedule for each swappable battery pack 102 based on analysed health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters. The health parameters comprise metrics such as state of health, internal resistance, and capacity retention. The usage parameters comprise the number of charge-discharge cycles, depth of discharge, and average power consumption patterns. The electrical parameters comprise real-time measurements of voltage, current, and energy efficiency. The thermal parameters comprise recorded surface and ambient temperatures and instances of temperature spikes. The safety parameters comprise overcurrent detection, short-circuit instances, and data related to thermal runaway events. The server arrangement 106 analyses the collected data to identify maintenance requirements, such as balancing cell charge, replacing worn-out components, or recalibrating monitoring systems within the battery management unit 104. Based on the analysis, the server arrangement 106 generates a timeline for maintenance activities, prioritizing battery packs 102 with critical conditions. For example, a battery pack 102 experiencing irregular voltage patterns or reduced state of charge may be scheduled for immediate inspection. The server arrangement 106 stores the maintenance schedule and communicates said schedule to system operators or other entities responsible for maintaining the swappable battery packs 102. The generated maintenance schedule minimizes operational disruptions by identifying the issues before they impact the performance or safety of the swappable battery packs 102, thereby extending their useful life and maintaining optimal system performance.
In an embodiment, the battery management unit 104 may dynamically adjust the charging and discharging cycles of each swappable battery pack 102 based on analysed health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters. The charging adjustment involves modifying parameters such as charging current, voltage thresholds, and charging duration based on the real-time condition of the battery cells. For example, a swappable battery pack 102 with elevated internal resistance may undergo reduced charging current to avoid excessive heat generation. Similarly, discharging cycles are adjusted by controlling the output current or limiting the depth of discharge to prevent over-discharge conditions, which could degrade the battery cells. Data such as the state of charge, thermal stability, and recent usage history is continuously analysed by the battery management unit 104 to optimize the charging and discharging process. For instance, during high ambient temperatures, the charging cycle may be slowed to mitigate risks of thermal stress. Furthermore, the dynamic adjustments account for the specific application in which the battery pack 102 is deployed, assuring energy delivery aligns with operational requirements. The adjustments are executed in real-time by the battery management unit 104 through the regulation of internal circuits and controls.
In an embodiment, the server arrangement 106 may apply historical data analytics to predict the remaining operational life and suggest a recycling strategy for each swappable battery pack 102. Historical data analytics involve evaluating past performance metrics such as cumulative charge-discharge cycles, trends in capacity fade, and patterns of internal resistance increase over time. Additional factors, comprising recorded thermal anomalies and instances of overcurrent events, are also incorporated into the analysis. The server arrangement 106 compares the historical data with predictive models to estimate the remaining lifespan of each battery pack 102. For example, a swappable battery pack 102 exhibiting a consistent decline in state of health below a predefined threshold may be flagged as nearing the end of the operational life. Based on the estimated remaining lifespan, the server arrangement 106 identifies the most appropriate recycling strategy. Recycling strategies comprise disassembling the battery pack 102 to recover valuable materials such as lithium or cobalt or repurposing the battery pack 102 for secondary applications with lower energy demands. For instance, a swappable battery pack 102 from an electric vehicle may be repurposed for use in stationary energy storage systems when its capacity becomes insufficient for high-performance mobility applications. The server arrangement 106 stores the predicted lifespan and recommended recycling strategy, which can be communicated to operators or recycling facilities.
In an embodiment, the server arrangement 106 may provide a strategy recommendation for each swappable battery pack 102 based on analysed health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters. The strategy recommendation involves determining the most appropriate course of action for each battery pack 102, such as reallocation to a different application, prioritization for maintenance, or withdrawal from active use. For instance, a battery pack 102 with high state of health and minimal usage history may be recommended for deployment in mobility solutions, while a battery pack 102 with reduced capacity but stable performance may be allocated to an energy storage system. The strategy recommendation also accounts for specific operational requirements of application domains, comprising power demand, energy efficiency, and safety conditions. The server arrangement 106 processes the analysed data and ranks swappable battery packs 102 based on their suitability for each application domain. Additionally, the strategy recommendation may comprise suggestions for optimized usage patterns, such as limiting charge-discharge cycles or adjusting operating temperatures, to extend the lifecycle of the battery packs 102. The server arrangement 106 stores the recommendation data and communicates said recommendation data to system operators or other entities responsible for managing the swappable battery packs 102.
In an embodiment, the server arrangement 106 may group the swappable battery packs 102 for coordinated deployment based on analysed health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters. The grouping process involves categorizing battery packs 102 with similar performance characteristics or operational conditions into clusters for optimized deployment. For example, battery packs 102 with high capacity and minimal wear may be grouped together for use in high-demand mobility applications, while battery packs 102 with reduced capacity may be allocated to lower-demand applications such as stationary energy storage. The server arrangement 106 analyses factors such as state of health, internal resistance, and thermal stability to determine grouping criteria. Additionally, operational parameters such as average load conditions and environmental factors are considered to enable compatibility within each group. The grouping facilitates efficient resource allocation by assuring that battery packs 102 with similar performance metrics are deployed together, minimizing inconsistencies and maximizing system reliability. The server arrangement 106 stores the grouping data and communicates deployment plans to operators or automated systems responsible for implementing the deployment.
In an embodiment, the server arrangement 106 may trigger an alert to a user based on the analysis of the thermal parameters and electrical parameters of the swappable battery packs 102. The thermal parameters include surface temperature, internal cell temperature, and ambient temperature, monitored by sensors integrated within the battery management unit 104. The electrical parameters encompass real-time measurements of voltage, current, and power output, providing insight into the operational condition of the battery pack 102 during charging and discharging cycles. The server arrangement 106 continuously receives these monitored parameters and evaluates them against predefined thresholds stored in the server database. For instance, if the surface temperature exceeds 45°C or if voltage patterns exhibit irregular fluctuations, the server arrangement 106 identifies a potential anomaly. Once an anomaly is detected, the server arrangement 106 generates an alert containing detailed information, including the specific battery pack 102 affected, the nature of the issue, and recommended corrective actions. For example, in the case of overheating, the alert may advise halting operations or initiating cooling measures. Alerts are communicated via visual displays, audible signals, or digital notifications to user devices.
In an exemplary use case scenario, a logistics company operates a fleet of electric delivery vehicles, energy storage systems, and battery swapping stations. The company uses swappable battery packs 102, each integrated with a battery management unit 104 that monitors health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters. The company has deployed 500 swappable battery packs 102 distributed across vehicles and storage units. The server arrangement 106, which is communicably coupled with all the battery management units 104, receives and processes real-time data from the battery packs 102 to assess their condition and determine their optimal application domains.
For instance, a swappable battery pack 102 currently deployed in an electric delivery vehicle transmits the following monitored data: health parameters indicate a state of health at 85% and internal resistance at 0.3 ohms; usage parameters comprise 750 charge-discharge cycles and an average depth of discharge of 65%; electrical parameters show a current voltage of 48V and a current of 100A; thermal parameters comprise a surface temperature of 35°C, internal cell temperature of 38°C, and ambient temperature of 30°C; and safety parameters report no incidents of short-circuits or overcurrent events. Upon analysing aforesaid data, the server arrangement 106 determines that the battery pack 102 is suitable for continued use in a mobility solution, such as an electric delivery vehicle, given the stable state of health and operational safety.
Another swappable battery pack 102, previously used in a vehicle, transmits data indicating a reduced state of health at 60%, internal resistance at 0.8 ohms, 1,200 charge-discharge cycles, and an average depth of discharge of 80%. Electrical parameters show a current voltage of 46V and a current of 95A, while thermal parameters indicate a surface temperature of 42°C and an internal cell temperature of 45°C under an ambient temperature of 32°C. Although no safety events are recorded, the thermal performance is nearing upper limits. Based on the analysis, the server arrangement 106 determines that the battery pack 102 is no longer optimal for mobility solutions due to its reduced capacity and elevated thermal profile. Instead, the server assigns this battery pack 102 to a domestic uninterrupted power supply (UPS) application, where its remaining capacity can sufficiently meet lower energy demands.
FIG. 2 illustrates a method for managing and monitoring swappable battery packs 102, in accordance with the embodiments of the present disclosure. At step 202, the method comprises monitoring the health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters of each swappable battery pack 102 through the battery management unit 104. The health parameters comprise metrics such as state of health, internal resistance, and capacity retention, which provide insights into the operational condition of the battery. The usage parameters represent the history of operations, comprising the total charge-discharge cycles, depth of discharge, and operational time under varying loads. The electrical parameters such as voltage, current, and power output are monitored to enable stable and optimal energy delivery. The thermal parameters comprise measurements of surface temperature, internal cell temperature, and ambient temperature to prevent overheating or thermal anomalies. The safety parameters comprise data on overcurrent detection, short-circuit events, and conditions that could lead to thermal runaway. The battery management unit 104 continuously collects the parameters using integrated sensors, such as thermistors, current sensors, and voltage dividers, and stores the data for subsequent analysis and processing.
At step 204, the method comprises communicably coupling the server arrangement 106 with each swappable battery pack 102. The server arrangement 106 establishes a communication link with the battery management unit 104 of each swappable battery pack 102. Communication is achieved through wired or wireless methods, such as Bluetooth, Wi-Fi, or cellular networks, enabling seamless data transmission between the swappable battery packs 102 and the server arrangement 106. The communicable coupling facilitates real-time or periodic transfer of monitored data, comprising health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters. The server arrangement 106 may handle multiple swappable battery packs 102 simultaneously, creating a centralized infrastructure for monitoring and managing battery operations across various applications.
At step 206, the method comprises acquiring the monitored health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters from each swappable battery pack 102 by the server arrangement 106. The server arrangement 106 retrieves the data collected by the battery management unit 104, comprising real-time and stored metrics, to create a database for analysis. The acquisition process involves systematic data polling or push notifications triggered by the battery management unit 104. For example, the battery management unit 104 may periodically transmit updated state-of-health data or notify the server arrangement 106 of abnormal voltage conditions. The acquired data is processed and stored within the server arrangement 106 for centralized management.
At step 208, the method comprises analysing, by the server arrangement 106, the health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters to determine an application domain for each swappable battery pack 102. The server arrangement 106 evaluates the monitored data to assess the performance, capacity, and safety conditions of each battery. The analysis identifies trends such as capacity fade, thermal stability, and charge-discharge efficiency to match the operational of battery profile with suitable application domains. For instance, a swappable battery pack 102 with high capacity and stable thermal performance may be allocated to a mobility solution, such as an electric vehicle, while a battery with moderate degradation may be assigned to an energy storage solution for renewable energy. Application domains comprise mobility solutions, energy storage solutions, battery swapping stations, domestic uninterrupted power supplies, and commercial uninterrupted power supplies. The server arrangement 106 uses predefined parameters and thresholds to classify the suitability of the swappable battery packs 102 for said application domains. The analysis enables efficient allocation of resources, extending the operational lifecycle of the swappable battery packs 102 by repurposing them for applications that align with their current performance and safety profiles.
In an embodiment, the server arrangement 106 may assign priority levels to each swappable battery pack 102 based on the health parameters and safety parameters. The priority levels are determined by evaluating the operational condition of each swappable battery pack 102 in relation to the performance, stability, and safety risks. The health parameters analysed comprise metrics such as state of health, internal resistance, and capacity retention. For example, a swappable battery pack 102 with a high state of health and minimal degradation is assigned a higher priority, making suitable for deployment in high-demand applications such as mobility solutions. Conversely, a battery pack 102 exhibiting reduced capacity retention or elevated internal resistance is assigned a lower priority, indicating its suitability for applications with reduced energy demands, such as stationary energy storage. The safety parameters assessed comprise data such as recorded overcurrent events, temperature anomalies, and thermal runaway risks. Battery packs 102 with stable safety profiles are prioritized for immediate use, while those with safety concerns are assigned lower priority or flagged for maintenance. The server arrangement 106 stores the priority levels in a centralized database and may use such information to guide deployment strategies or maintenance schedules. Priority levels are dynamically updated based on real-time and historical data to reflect the current operational status of each swappable battery pack 102, enabling optimal allocation of resources across various application domains.
In an embodiment, the server arrangement 106 may recalibrate the electrical parameters, thermal parameters, and safety parameters of each swappable battery pack 102 based on weather data. The recalibration process adjusts the operating thresholds and performance metrics to account for environmental factors such as ambient temperature, humidity, and atmospheric pressure. Weather data is acquired from external sources, such as local weather stations or integrated environmental sensors, and analysed in conjunction with the monitored parameters of each swappable battery pack 102. Electrical parameters such as voltage and current thresholds are recalibrated to optimize energy delivery under varying environmental conditions. For example, during periods of high ambient temperatures, the voltage threshold may be adjusted downward to prevent overheating. Thermal parameters, comprising surface and internal cell temperature thresholds, are recalibrated to mitigate thermal stress caused by extreme heat or cold. Safety parameters, such as overcurrent and thermal runaway thresholds, are recalibrated to maintain safe operation under changing weather conditions. For instance, in cold weather, the recalibration may account for reduced chemical activity within the battery cells, adjusting the safety parameters accordingly. The recalibration data is stored by the server arrangement 106 and used to dynamically update the operating settings of the swappable battery packs 102 through their associated battery management units 104.
In an embodiment, the server arrangement 106 may determine an adaptive charging policy for each swappable battery pack 102 based on analysed health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters. The adaptive charging policy involves dynamically adjusting the charging current, voltage, and duration to align with the current condition and performance profile of each swappable battery pack 102. The health parameters analysed comprise the state of health and internal resistance, which determine the capacity of battery to accept and retain charge. For instance, a battery pack 102 with reduced state of health may undergo a slower charging cycle to minimize stress on the cells. Usage parameters, such as the number of charge-discharge cycles and depth of discharge, are considered to optimize the charging pattern for long-term reliability. Electrical parameters, comprising real-time voltage and current levels, guide adjustments to enable efficient energy transfer during charging. Thermal parameters, such as surface and ambient temperatures, are monitored to avoid overheating during the charging process. Safety parameters, such as overvoltage and overcurrent thresholds, are incorporated to prevent unsafe charging conditions. The server arrangement 106 processes the data and determines a customized charging strategy for each swappable battery pack 102, which is then communicated to the battery management unit 104.
In an embodiment, the system 100 to manage and monitor the swappable battery packs 102 achieves improved operational efficiency by enabling continuous monitoring of the health, usage, electrical, thermal, and safety parameters of each swappable battery pack 102. The integration of the battery management unit 104 with each swappable battery pack 102 provides real-time data acquisition, facilitating the early detection of anomalies such as capacity degradation, overcurrent events, or thermal instability. The server arrangement 106, communicably coupled with each swappable battery pack 102, centralizes data processing, enabling analysis to optimize application-specific deployment. The selection of application domains based on performance parameters allows efficient utilization of the battery packs 102, reducing waste and extending their operational lifecycle across diverse environments, such as mobility solutions, energy storage systems, and uninterrupted power supplies.
In a preceding embodiment, the server arrangement 106 generates maintenance schedules for the swappable battery packs 102 based on analysed parameters, resulting in proactive identification and resolution of the performance issues. Aforesaid maintenance schedules minimize downtime and prevents premature failure, enabling sustained system reliability. By dynamically prioritizing maintenance tasks, the system 100 optimizes resource allocation, avoiding unnecessary inspections for battery packs 102 in stable operational condition while addressing critical needs promptly.
In a preceding embodiment, the battery management unit 104 dynamically adjusts charging and discharging cycles based on real-time analysis of monitored parameters, optimizing energy transfer and mitigating stress on battery cells. The adjustment reduces risks such as overcharging, excessive discharge, and overheating, contributing to longer battery lifespan and stable energy delivery under varying operational conditions.
In a preceding embodiment, the application of historical data analytics by the server arrangement 106 enables accurate predictions of remaining operational life for the swappable battery packs 102. The predictive capability supports timely decisions regarding recycling strategies, assuring that battery materials are repurposed or recovered efficiently. The recycling recommendations reduce environmental impact while maximizing the lifecycle utility of the battery packs 102.
In an embodiment, the server arrangement 106 provides a strategy recommendation for each swappable battery pack 102, aligning its deployment with its performance metrics and application suitability. The targeted approach enhances the effective utilization of battery resources, making sure that high-performing batteries are allocated to demanding applications while moderately degraded batteries are repurposed for less intensive uses.
In another embodiment, the system 100 enables the server arrangement 106 to group swappable battery packs 102 for coordinated deployment, streamlining operational efficiency across multiple application domains. Grouping battery packs 102 with similar performance characteristics minimizes operational inconsistencies and affirms balanced energy distribution in clustered applications, such as battery swapping stations or commercial energy storage solutions.
In an embodiment, the server arrangement 106 triggers alerts based on the analysis of thermal and electrical parameters, providing timely notifications of risks. The alerts enable proactive intervention to prevent safety hazards such as thermal runaway or short circuits, maintaining the reliability and safety of the system 100 while enabling uninterrupted operation.
In a further embodiment, the method for managing and monitoring the swappable battery packs 102 enables tracking of critical parameters through the battery management unit 104, enabling data acquisition and analysis. The communicable coupling of the server arrangement 106 with each swappable battery pack 102 establishes seamless data transmission for centralized management. The acquisition and analysis of monitored data by the server arrangement 106 affirm accurate allocation of each swappable battery pack 102 to a suitable application domain, maximizing its operational potential.
In another embodiment, the server arrangement 106 assigns priority levels to the swappable battery packs 102, enabling strategic allocation based on health and safety parameters. The prioritization optimizes system performance by focusing resources on batteries with the highest operational demands or addressing those requiring immediate attention for safety reasons.
In another embodiment, the recalibration of electrical, thermal, and safety parameters based on weather data by the server arrangement 106 adapts the performance thresholds of the swappable battery packs 102 to environmental conditions. The dynamic adjustment prevents operational failures due to extreme temperatures or humidity, enabling consistent energy delivery and safety under diverse environmental scenarios.
In another embodiment, the determination of an adaptive charging policy for each swappable battery pack 102 by the server arrangement 106 achieves optimal charging cycles tailored to the real-time condition of the battery cells. Said approach reduces thermal and chemical stress, enhances energy transfer efficiency, and extends the operational life of the swappable battery packs 102, supporting sustainable energy management.
Mr. Jacob is the owner and manager of 1,000 swappable battery packs 102 deployed across multiple domains, including mobility solutions (e.g., electric vehicles), energy storage systems, battery swapping stations, domestic uninterrupted power supply (UPS), commercial UPS, and agricultural energy systems. These swappable batteries are monitored and managed using the described system, which includes battery management units (BMUs) on each battery pack and a centralized server arrangement. Each swappable battery pack 102 is associated with a battery management unit 104 that continuously monitors critical parameters, including health parameters, usage parameters, electrical parameters, thermal parameters, and safety parameters. These monitored parameters are communicated to a server arrangement 106, which is communicably coupled with each swappable battery pack 102. The server arrangement 106 acquires and analyzes the monitored parameters to determine the most suitable application domain for each swappable battery pack 102. For instance, in mobility solution operations, the system 100/ server arrangement 106 identifies that a subset of swappable battery packs 102 is nearing the end of its optimal lifecycle for high-demand applications, such as powering electric vehicles. The analysis performed by the server arrangement 106, based on health parameters and usage data, reveals that while these swappable battery packs 102 may no longer provide peak performance required for mobility solutions, they remain well-suited for deployment in lower-demand applications such as domestic uninterrupted power supplies, where the energy requirements are less rigorous, or as backup energy storage for commercial uninterrupted power supply systems. The intelligent repositioning capability of system 100, enabled by server arrangement 106, provides significant advantages. Instead of prematurely recycling swappable battery packs 102 or discarding them as waste, Mr. Jacob can extend their operational lifecycle by redeploying them to application domains that align with their current performance levels to optimize resource utilization and provides a cost-effective solution for his operations across mobility solutions, energy storage solutions, battery swapping stations, and uninterrupted power supply systems. Additionally, the server arrangement 106 generates a maintenance schedule for each swappable battery pack 102 based on the analyzed parameters. This ensures that necessary maintenance actions are performed proactively, minimizing the risk of unexpected failures and maximizing the reliability of the fleet. Furthermore, the battery management unit 104 dynamically adjusts the charging and discharging cycles of each swappable battery pack 102 to enhance their longevity while maintaining safety and operational efficiency. In cases where the server arrangement 106 identifies critical thermal or electrical anomalies in any swappable battery pack 102, server arrangement 106 triggers alerts to notify Mr. Jacob promptly to improve safety and mitigate potential risks and maintain operational safety standards. By enabling the repositioning of swappable battery packs 102 across various application domains and extending their useful life, the system 100 delivers substantial economic and operational benefits. Mr. Jacob gains a highly optimized fleet management solution, ensuring that every swappable battery pack 102 is utilized to full potential while maintaining sustainability and reliability across his diverse operations. Thus, system 100 enables efficient battery pack management, reducing waste, enhancing cost efficiency, and improving adaptability of swappable battery packs 102 based on evolving operational demands.
The following table highlights exemplary values for each parameter category and demonstrates how the server arrangement 106 uses these values to assign swappable battery packs 102 to appropriate application domains.
Parameter Mobility Solution Energy Storage Solution Battery Swapping Station Domestic UPS Commercial UPS
State of Health (SoH) (%) 80-100 70-90 60-80 50-70 50-70
Cycle Count <500 500-1000 1000-1500 1500-2000 1500-2000
Voltage Stability (V) High (>95%) Moderate (85-95%) Moderate (85-95%) Low (75-85%) Low (75-85%)
Temperature Range (°C) -10 to +40 -5 to +50 -10 to +45 0 to +35 0 to +35
Discharge Rate (C) High (2-3C) Low (0.5-1C) Medium (1-2C) Very Low (<0.5C) Very Low (<0.5C)
Safety Index >95% >90% >85% >80% >80%
Energy Retention
(%) 90-100 80-90 70-80 60-70 60-70

System 100 enables categorization of swappable battery packs 102 based on monitored parameters, enabling efficient allocation to appropriate application domains. The server arrangement 106 leverages data from the battery management unit 104, which monitors critical parameters such as State of Health (SoH), cycle count, voltage stability, temperature range, discharge rate, and safety index. These parameters are analyzed to determine the operational suitability of each swappable battery pack 102 for domains including, but not limited to, mobility solutions, energy storage solutions, battery swapping stations, domestic uninterrupted power supplies, and commercial uninterrupted power supplies.
For instance, swappable battery packs 102 with a high SoH (e.g., 80-100%), low cycle counts (e.g., <500), and high discharge rates (e.g., 2-3C) are assigned to mobility solutions, where performance demands are highest. In contrast, battery packs 102 with moderate SoH (e.g., 70-90%) and cycle counts (e.g., 500-1000) are better suited for energy storage applications, where consistent, long-term energy retention is critical. As battery packs 102 approach the end lifecycle for high-demand domains, such as mobility solutions, such battery packs 102 can be repositioned to less demanding domains, such as domestic uninterrupted power supplies, where parameters like SoH (e.g., 50-70%) and discharge rates (e.g., <0.5C) remain acceptable.
The categorization process performed by the server arrangement 106 involves multiple stages for assignment of swappable battery packs 102. The battery management unit 104 continuously monitors and transmits parameter data for each battery pack 102 to the server arrangement 106. The server arrangement 106 compares the monitored values against predefined thresholds for each application domain. By analyzing the parameters holistically, server arrangement 106 assigns battery packs 102 to domains where their current performance characteristics align with the domain's operational requirements. For example, battery pack 102 exhibiting reduced voltage stability (e.g., 85%) and moderate SoH (e.g., 75%) may be reassigned from a mobility solution to an energy storage domain, where such parameters remain viable. The server arrangement 106 identifies swappable battery packs 102 nearing the end of their optimal performance in a given domain and recommends their reassignment to less demanding domains. For instance, a battery pack 102 used in a mobility solution, upon reaching a SoH of 72% and exceeding 500 cycles, may be reassigned to an energy storage application, extending its operational lifecycle while maintaining efficiency. Such dynamic allocation minimizes waste, optimizes resource utilization, and ensures that battery packs 102 contribute to the sustainability and economic viability of system 100. Through this intelligent categorization and repositioning, the system 100 delivers enhanced fleet management capabilities, enabling users to maintain reliable and efficient operations across diverse application domains.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combination of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non- exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:WE CLAIM:
1. A system 100 to manage and monitor the swappable battery packs, the system 100 comprises:
the swappable battery packs 102, wherein each swappable battery pack 102 is associated with a battery management unit 104 to monitor the health parameters, the usage parameters, the electrical parameters, the thermal parameters and the safety parameters;
a server arrangement 106 is communicably coupled with each swappable battery pack, wherein the server arrangement 106:
acquires the monitored the health parameters, the usage parameters, the electrical parameters, the thermal parameters and the safety parameters; from each swappable battery pack 102;
analyses the health parameters, the usage parameters, the electrical parameters, the thermal parameters and the safety parameters to an application domain for each of battery pack 102, wherein the application domain is selected from a mobility solution, an energy storage solution, a battery swapping station, a domestic uninterrupted power supply, a commercial uninterrupted power supply.
2. The system 100 as claimed in claim 1, wherein the server arrangement 106 generates a maintenance schedule for each swappable battery pack 102 based on the analysed health parameters, the usage parameters, the electrical parameters, the thermal parameters and the safety parameters.
3. The system 100 as claimed in claim 1, wherein the battery management unit 104 dynamically adjusts the charging and the discharging cycles of each swappable battery pack 102 based on the analysed health parameters, the usage parameters, the electrical parameters, the thermal parameters and the safety parameters.
4. The system 100 as claimed in claim 1, wherein the server arrangement 106 applies historical data analytics to predict a remaining operational life and suggests a recycling strategy for each swappable battery pack 102.
5. The system 100 as claimed in claim 1, wherein the server arrangement 106 provides a strategy recommendation for each swappable battery pack 102.
6. The system 100 as claimed in claim 1, wherein the server arrangement 106 groups the swappable battery packs 102 for coordinated deployment.
7. The system 100 as claimed in claim 1, wherein the server arrangement 106 triggers an alert to a user based on analysis of the thermal parameters and the electrical parameters.
8. A method 200 for managing and monitoring swappable battery packs 102, the method comprising:
monitoring, through the battery management unit 104, the health parameters, the usage parameters, the electrical parameters, the thermal parameters, and the safety parameters of each swappable battery pack 102;
communicably coupling the server arrangement 106 with each swappable battery pack 102;
acquiring, by the server arrangement 106, the monitored health parameters, the usage parameters, the electrical parameters, the thermal parameters, and the safety parameters from each swappable battery pack 102;
analysing, by the server arrangement 106, the health parameters, the usage parameters, the electrical parameters, the thermal parameters, and the safety parameters to determine an application domain for each battery pack 102, wherein the application domain is selected from a mobility solution, an energy storage solution, a battery swapping station, a domestic uninterrupted power supply, and a commercial uninterrupted power supply.
9. The method 200 as claimed in claim 8, wherein the server arrangement 106 assigns priority levels to each swappable battery pack 102 based on the health parameters and the safety parameters.
10. The method 200 as claimed in claim 8, wherein the server arrangement 106 recalibrates the electrical parameters, the thermal parameters and the safety parameters based on weather data.
11. The method 200 as claimed in claim 8, wherein the server arrangement 106 determines an adaptive charging policy for each swappable battery pack 102.