DESC:MODULAR BATTERY MANAGEMENT SYSTEM FOR BATTERY PACK(S)
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202421001998 filed on 10/01/2024, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
Generally, the present disclosure relates to energy storage solutions for mobility and stationary applications. Particularly, the present disclosure relates to a Battery Management System (BMS) of battery packs of the electric vehicle(s).
BACKGROUND
The increasing demand for more economical and efficient vehicles, along with consumer preferences for higher-performance batteries, compels automobile manufacturers to innovate in order to satisfy these needs. As a result, the automotive industry has consistently worked to improve battery packs with modular battery management systems, aiming for better safety and simplified maintenance and servicing.
Conventionally, a Battery Management System (BMS) usually comprises of integrated components that function as a single, cohesive unit to manage various aspects of a battery pack. The primary components of a BMS include a battery monitoring unit (BMU), a controller, a balancing circuit, and a protection circuit. The Battery Monitoring Unit (BMU) oversees voltage, current, and temperature monitoring of individual cells. Further, the controller makes decisions based on data from the BMU and the balancing circuit ensures uniform charge across all battery cells. Subsequently, the protection circuit safeguards the powerpack and/or system associated from the conditions such as overcharging, over-discharging, over current, over voltage, overheating and so forth. The components are integrated as a single unit, and the entire BMS is designed to function as a single, monolithic unit with a simplified design making the initial system setup faster and less complex.
However, there are certain problems associated with the existing or above-mentioned the battery management systems. For instance, as all the components are integrated, failure in any one component requires replacing of the entire BMS, thereby making the repairing of the BMS costly and time-consuming. Further, the above-mentioned BMS integration does not allow for easy customization for different battery configurations or applications, thereby limiting the adaptability to evolve with modern battery management system technologies. Furthermore, the integration of all components into one unit increases the risk of a single point of failure, and thereby reduces the safety of the entire power pack.
Therefore, there exists a need of a battery management system that is flexible, safe, and overcomes one or more problems as mentioned above.
SUMMARY
An object of the present disclosure is to provide a self-diagnostic Battery Management System (BMS) of a powerpack.
Another object of the present disclosure is to provide a modular Battery Management System (BMS).
In accordance with an aspect of the present disclosure, there is provided a self-diagnostic Battery Management System (BMS) for a powerpack, the BMS comprises:
- a voltage sensing module;
- a current sensing module;
- a temperature sensing module; and
- a processing module,
wherein the voltage sensing module, the current sensing module, the temperature sensing module, and the processing module are in physical isolation.
The self-diagnostic Battery Management System (BMS) of a powerpack, as described in the present disclosure, is advantageous in terms of providing a BMS with enhanced modularity and reliability. The modular design of the BMS with each module separately mounted and isolated, enables easy maintenance and upgrades. Further, the physical isolation of a voltage sensing module, current sensing module, temperature sensing module, and processing module ensures that each module operates independently, reducing the risk of interference between components and thereby enhancing the reliability of the BMS.
Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
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:
Figures 1 and 2 illustrate block diagrams of a self-diagnostic Battery Management System (BMS) of a powerpack, in accordance with different embodiments of the present disclosure.
Figure 3 illustrates a block diagram of a connection between a temperature sensing module and a powerpack, in accordance with an embodiment 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 recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
As used herein, the terms “battery management system” and “BMS” are used interchangeably and refer to an electronic system that manages and monitors the performance, health, and safety of the vehicle battery pack. Further, the BMS ensures optimal battery operation by managing various functions such as (but not limited to) charging, discharging, temperature control, and state of charge assessment. Furthermore, the BMS protects the battery from potential hazards such as overcharging, deep discharging, and thermal runaway, thereby enhancing battery life and performance.
As used herein, the term “powerpack” refers to an assembled unit of a plurality of cell arrays that are connected electrically to form a larger energy storage capable of delivering the required amount of energy for high-power applications. The battery modules may be arranged in series or parallel configurations depending on the desired voltage and capacity requirements. The battery modules of the powerpack connected in series increase the overall voltage of the energy storage system. The electrical connections in the powerpack are formed by connecting the terminals of the battery cells with bus bars. Furthermore, in addition to the individual cells, a powerpack also includes circuitry for balancing the charge levels of the cells, managing the charging and discharging processes, and providing safety features such as overcharge and over-discharge protection. The powerpack, along with the associated electronics and packaging, forms the core component of an energy storage system, enabling the efficient and reliable storage and delivery of electrical energy.
As used herein, the term “voltage sensing module” refers to a component that monitors and measures the voltage levels of individual battery cells or groups of cells within the battery pack. The voltage sensing module comprises components such as a voltage divider circuit, Analog-to-Digital Converters (ADC), and reference voltage sources. The voltage divider reduces the voltage amplitude to a safety level for easy interpretation by subsequent stages comprising microcontroller or processing unit. The ADC converts the analog voltage signal into a digital value for processing by the processing unit. Further, the reference voltage source ensures accurate measurement by establishing a standard voltage for comparison with the sensed voltage. Furthermore, the working of the voltage sensing module involves continuously monitoring the input voltage, converting the input voltage to a digital signal of an appropriate amplitude, and transmitting the generated digital signal to the microcontroller for further analysis or feedback control, such as triggering an alarm or adjusting system parameters based on the voltage level.
As used herein, the term “current sensing module” refers to a component that monitors the flow of electrical current into and out of the battery pack. Specifically, the current sensing module measures a small voltage drop across a low-resistance element proportional to the current passing through the resistance. Subsequently, the measured voltage is amplified by an amplifier to a level suitable for measurement and converted to a digital value for processing via the processing unit for further analysis. The current sensing module continuously monitors the current flow and provides real-time feedback, such as triggering alerts for overcurrent conditions or controlling systems to adjust power usage.
As used herein, the term “temperature sensing module” refers to a component that monitors the temperature of individual battery cells or the entire battery pack. The temperature sensing module comprises a temperature sensor (such as, a thermistor, thermocouple, or Resistance Temperature Detector (RTD)), an amplifier, and an Analog-to-Digital Converter (ADC). The temperature sensor detects changes in temperature and converts them into a corresponding electrical signal. The generated signal is then amplified by the amplifier to amplify the signal to an appropriate level for measurement and converted to a digital format via ADC. The temperature sensing module continuously monitors the temperature, allowing for real-time feedback to adjust system parameters (like triggering cooling or heating mechanisms) or to provide warnings during exceedance of the temperature with respect to a safe threshold.
As used herein, the term “processing unit” refers to a central component of an embedded system or electronic device responsible for managing and executing tasks based on input data, making decisions, and controlling other system components. The processing unit comprises a microcontroller (MCU) or microprocessor (CPU), memory modules (RAM and ROM), and input/output interfaces. The microcontroller or processor executes software instructions to process data from sensors (such as, but not limited to, temperature, current, or voltage), perform calculations, and make control decisions. The memory stores the program code and runtime data, and the input/output interfaces allow communication with other devices or modules. The processing unit performs by receiving sensor inputs, processing them according to predefined algorithms or logic, and then sending control signals to actuators or other parts of the system, enabling the required functions.
As used herein, the term “mounting member” refers to a structural component designed to secure and support various modules and components, such as, but not limited to, the voltage sensing module, current sensing module, temperature sensing module, and processing unit. The mounting member serves as the physical framework that allows the critical system modules to be securely attached and positioned within the BMS enclosure, ensuring proper alignment and ease of maintenance. The mounting member is designed with specific features like brackets, slots, or screws to accommodate the size and shape of each module, preventing movement or disconnection during operation, lead to measurement inaccuracies or system failure.
As used herein, the term “busbar” refers to a conductive material for distributing electrical power between the battery cells and other electrical components of the vehicle power system. The busbar acts as a bridge to connect the battery cells in series or parallel arrangements, enabling the efficient flow of electricity from the battery to the motor. The busbar ensures low resistance, reduces energy loss, and prevents overheating in the electrical circuits of the vehicle. Further, the busbar controls high currents without causing excessive voltage to drop, ensuring the stability and reliability of the vehicle power system. Moreover, the busbar has features such as (but not limited to) insulation, heat sinks, and thermal management solutions to mitigate risks associated with electrical faults, short circuits, or thermal runaway. Therefore, by ensuring a safe and effective power distribution system, the busbar acts as an integral component that contribute to the overall performance, durability, and safety of the electric vehicle energy storage and delivery system.
As used herein, the terms “switching devices”, and “switches” are used interchangeably and refer to the components that controls the flow of electricity to and from the battery pack, ensuring safe and efficient transmission from the battery pack. The switching devices comprise MOSFETs (Metal-Oxide-Semiconductor Field-Effect Transistors), relays, and contactors. The MOSFETs are used for high-speed switching and controlling charge and discharge currents. The relays and contactors isolate the battery during fault conditions or during switching between charge and discharge modes. The switching devices functions by receiving control signals from the BMS, which monitors battery health, temperature, and voltage. When a specific condition (such as overvoltage, undervoltage, or thermal overload) is detected, the switching devices open or close the circuit, either allowing or cutting off power to the battery or external load, thus protecting the battery from damage and ensuring optimal performance.
As used herein, the term “thermal sensor” refers to a component that monitoring the temperature of various parts of the system, such as the battery cells, voltage sensing module, current sensing module, and processing unit. The thermal sensors are critical for ensuring the system operates within safe temperature ranges, as extreme temperatures may affect the performance and safety of the battery pack. Further, by detecting temperature variations, thermal sensors provide real-time data to the processing unit, enabling it to make informed decisions regarding cooling or heating mechanisms to maintain optimal battery performance and prevent thermal runaway or damage.
As used herein, the term “cell array” refers to a structured arrangement of individual battery cells, configured in series and/or parallel to form a battery pack. Each cell in the array is a single electrochemical unit capable of storing and releasing electrical energy. The cells are the building blocks of the battery system, and the configuration determines the overall voltage, capacity, and energy density of the pack. The cell array is designed to optimize the performance of the EV, ensuring that the battery pack provides sufficient energy for the vehicle operation while maintaining safety and efficiency. The BMS monitors and manages the individual cells within the array to ensure uniform performance and prevent overcharging, deep discharging, or overheating.
In accordance with an aspect of the present disclosure, there is provided a self-diagnostic Battery Management System (BMS) for a powerpack, the BMS comprises:
- a voltage sensing module;
- a current sensing module;
- a temperature sensing module; and
- a processing module,
wherein the voltage sensing module, the current sensing module, the temperature sensing module, and the processing module are in physical isolation.
Referring to figure 1, in accordance with an embodiment, there is described a self-diagnostic Battery Management System (BMS) 100 of a powerpack 102. The BMS 100 comprises a voltage sensing module 104, a current sensing module 106, a temperature sensing module 108, and a processing module 110. Further, the voltage sensing module 104, the current sensing module 106, the temperature sensing module 108, and the processing module 110 are in physical isolation. Furthermore, the BMS 100 comprises a mounting member 112 configured to secure the voltage sensing module 104, the current sensing module 106, the temperature sensing module 108, and the processing module 110 within the BMS 100. Furthermore, the processing module 110 is coupled with the voltage sensing module 104, the current sensing module 106, and the temperature sensing module 108, via a plurality of busbars 114.
The Battery Management System (BMS) 100 with components in physical isolation and coupled via busbars 114 provides significant improvements in terms of modularity, reliability, and performance of the BMS. The physical isolation of the voltage sensing module 104, current sensing module 106, temperature sensing module 108, and processing module 110 ensures that each module operates independently, reducing the risk of interference between components. Further, the isolation enhances the overall performance of the BMS 100, ensuring that each module operates at its optimal condition without being affected by the electrical noise or thermal disturbances generated by other components. Furthermore, the mounting member 112 securely holds these modules in place, preventing mechanical movement and potential damage, thereby maintaining system integrity, particularly in high-vibration environments like electric vehicles. Furthermore, the use of busbars 114 to couple the modules ensures a reliable, low-resistance electrical connection between the sensing modules and the processing unit 110. The above-mentioned setup allows for efficient communication and data transfer for BMS 100 to monitor and control the battery pack state accurately. Additionally, the modular design of the BMS 100 with each module is separately mounted and isolated, enables easy maintenance and upgrades. Moreover, the design makes the BMS 100 adaptable to future advancements, as newer or more efficient module integration is possible without requiring a complete redesign of the system.
In an embodiment, the BMS 100 comprises a mounting member 112 configured to secure the voltage sensing module 104, the current sensing module 106, the temperature sensing module 108, and the processing module 110 within the BMS 100. The inclusion of a mounting member 112 within the Battery Management System (BMS) 100 provides a robust and organized structure for securely housing critical components such as the voltage sensing module 104, current sensing module 106, temperature sensing module 108, and processing module 110. The above-mentioned configuration ensures that all the modules are steadily fixed in place, minimizing the risk of damage from vibrations, shocks, or mechanical stress that occurs during vehicle operation. Further, the effective isolation of each module on the mounting member 112 also facilitates enhanced thermal management and reduces the risk of overheating or short-circuiting due to improper placement of sensitive electronic components. Furthermore, the mounting member 112 enables easier integration of the BMS 100 within the power pack 102 or vehicle system, ensuring a streamlined and compact design. Furthermore, the inclusion of the mounting member 112 simplifies the assembly process of the BMS 100, as sensing and processing module 110 is securely fixed in the correct orientation, thereby, reducing the installation errors. Additionally, the mounting member 112 contributes to the modularity of the BMS 100 design as the replacement or upgradation of individual modules becomes efficient without impacting the integrity of the entire system. Consequently, the maintenance and upgradability of the BMS 100 are improved, leading to reduced downtime and better long-term performance of the vehicle.
In an embodiment, the processing module 110 is coupled with the voltage sensing module 104, the current sensing module 106, and the temperature sensing module 108, via a plurality of busbars 114. The coupling of the processing module 110 with the voltage sensing module 104, current sensing module 106, and temperature sensing module 108 via busbars 114 provides efficient and reliable communication between the various sensors and the processing module 110. The busbars 114 serve as a low-resistance, high-conductivity pathway for voltage signals, facilitating the rapid transmission of the voltage, current, and temperature measurements from the sensors to the processing module 110. Consequently, the direct compact interconnection ensures that the processing module receives accurate and real-time data from all sensing units, allowing for precise monitoring and control of the battery pack 102 performance. Further, the busbars 114 minimize signal loss and ensure minimal interference, and thereby maintain the integrity of sensor data.
In an embodiment, the plurality of busbars 114 are removably connected with the voltage sensing module 104, the current sensing module 106, the temperature sensing module 108, and the processing module 110. The removable connection of the plurality of busbars 114 enhances the flexibility and modularity of the BMS 100. The above-mentioned configuration allows for easy disconnection and reconnection of the busbars 114, which is particularly beneficial during maintenance or replacement of individual components. Further, the removable busbars 114 provide a streamlined approach to servicing the system, as specific modules are easily isolated, and issues are addressed without the need to dismantle the entire setup. The removable connection also supports a simplified assembly process, enabling faster and more efficient integration of the BMS 100.
Referring to figure 2, in accordance with an embodiment, there is described a self-diagnostic Battery Management System (BMS) 100 of a powerpack 102. The BMS 100 comprises a voltage sensing module 104, a current sensing module 106, a temperature sensing module 108, and a processing module 110. Further, the voltage sensing module 104, the current sensing module 106, the temperature sensing module 108, and the processing module 110 are in physical isolation. Furthermore, the BMS 100 comprises a mounting member 112 configured to secure the voltage sensing module 104, the current sensing module 106, the temperature sensing module 108, and the processing module 110 within the BMS 100. Furthermore, the processing module 110 is coupled with the voltage sensing module 104, the current sensing module 106, and the temperature sensing module 108, via a plurality of busbars 114. Furthermore, the plurality of busbars 114 are connected with the voltage sensing module 104, the current sensing module 106, the temperature sensing module 108, and the processing module 110, via a plurality of switching devices 116. The connection of the plurality of busbars 114 via switching devices 116 enables dynamic control of the electrical pathways within the Battery Management System (BMS) 100. The switching devices 116 allow for the precise routing of electrical signals between the modules, enabling the BMS 100 to selectively engage or disengage the connected modules based on operational requirements. Consequently, the flexibility ensures that the required modules are active during specific phases of battery management, thereby optimizing energy consumption, enhancing system responsiveness, and allowing for specific charging or discharging strategies. Additionally, switching devices 116 improves fault isolation capabilities, as the system isolates the malfunctioning module without affecting the entire BMS 100, thereby preventing further damage and improving the overall reliability.
Referring to figure 3, in accordance with an embodiment, there is described a connection between a temperature sensing module 108 and a powerpack 102. The temperature sensing module 108 comprises a plurality of thermal sensors 118A-118N disposed on at least one cell array 120A-120N of the powerpack 102. The connection of the temperature sensing module 108 to a plurality of thermal sensors 118A-118N enables real-time, precise monitoring of the temperature at various points throughout the power pack 102. The thermal sensors 118A-118N provide temperature measurements at different cells, ensuring that any temperature variation across the cell array 120A-120N is accurately detected. Further, the data is fed into the temperature sensing module 108, the system is able to continuously track the thermal behaviour of each cell, allowing the Battery Management System (BMS) 100 to identify any hot spots or temperature imbalances indicating potential issues, such as overcharging or thermal runaway. Therefore, the enhanced monitoring capability supports more accurate temperature regulation and early detection of abnormal conditions, thus improving the overall safety and performance of the battery.
In an embodiment, the processing unit 110 is configured to receive input from the voltage sensing module 104, the current sensing module 106, and/or the temperature sensing module 108. The processing unit 110 configured to receive input from the voltage sensing module 104, current sensing module 106, and temperature sensing module 108 provides a technical effect by enabling centralized and coordinated management of critical battery parameters. The processing unit 110 analyzes real-time data from the voltage, current, and temperature sensors to monitor the health and performance of the power pack 102. Further, by integrating the input data from the modules, the processing unit 110 accurately assesses the battery state of charge (SOC), state of health (SOH), and thermal conditions. Therefore, real-time data processing enhances the system's responsiveness to changes in operating conditions, ensuring the battery operates within safe limits and maintains its performance over time.
In an embodiment, the processing unit 110 is configured to identify at least one fault associated with the voltage sensing module 104, the current sensing module 106, and/or the temperature sensing module 108. The processing unit 110, configured to identify faults enables the real-time detection of the malfunction or inconsistency in the above-mentioned sensing modules. The continuous monitoring of the data received from the modules allows the processing unit 110 to analyze parameters such as voltage, current, and temperature for abnormal patterns or readings indicating a fault. For instance, the detection of sudden spikes or drops in voltage, irregular current flow, or temperature variations beyond the safe operating threshold are detected by the processing module 110. The early detection allows the system to identify issues such as sensor malfunctions, wiring faults, or potential system failures and thereby prevents damage to the battery pack. Further, the identification of the faults promptly allows the processing unit 110 for immediate corrective actions, such as isolating faulty sensors, triggering alerts, or adjusting charging/discharging parameters to prevent further damage. Consequently, the Battery Management System (BMS) 100 operates efficiently, maintaining optimal performance and protecting the battery from faults.
In an embodiment, the processing unit 110 is configured to electrically isolate the voltage sensing module 104, the current sensing module 106, and/or the temperature sensing module 108, based on the identified fault, by operating the plurality of switching devices 116. The processing unit 110 detects a fault in one of the sensing modules to disconnect the affected module using the switching devices 116 and thereby prevents faulty data from impacting the overall battery management process. The isolation allows the BMS 100 to maintain its functionality and continue monitoring the other parameters (voltage, current, and temperature) without interruption, ensuring that the system remains operational in the event of one or more sensor failures. The immediate response to the faults minimizes the risk of incorrect battery management decisions and thereby preventing lead to damage, reduced performance, or safety hazards. Further, the isolation reduces the risk of cascading failures that affect the entire power pack 102, ensuring that the system remains safe and effective.
Based on the above-mentioned embodiments, the present disclosure provides significant advantages such as (but not limited to) enhanced modularity and reliability of the battery management system, allowing easy maintenance and upgrades of the modules mounted on the mounting member of the battery management system.
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 combinations 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”, and “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 self-diagnostic Battery Management System (BMS) (100) for a powerpack (102), the BMS (100) comprises:
- a voltage sensing module (104);
- a current sensing module (106);
- a temperature sensing module (108); and
- a processing module (110),
wherein the voltage sensing module (104), the current sensing module (106), the temperature sensing module (108), and the processing module (110) are in physical isolation.

2. The BMS (100) as claimed in claim 1, wherein the BMS (100) comprises a mounting member (112) configured to secure the voltage sensing module (104), the current sensing module (106), the temperature sensing module (108), and the processing module (110) within the BMS (100).

3. The BMS (100) as claimed in claim 1, wherein the processing module (110) is coupled with the voltage sensing module (104), the current sensing module (106), and the temperature sensing module (108), via a plurality of busbars (114).

4. The BMS (100) as claimed in claim 3, wherein the plurality of busbars (114) are removably connected with the voltage sensing module (104), the current sensing module (106), the temperature sensing module (108), and the processing module (110).

5. The BMS (100) as claimed in claim 3, wherein the plurality of busbars (114) are connected with the voltage sensing module (104), the current sensing module (106), the temperature sensing module (108), and the processing module (110), via a plurality of switching devices (116).

6. The BMS (100) as claimed in claim 1, wherein the temperature sensing module (108) comprises a plurality of thermal sensors (118) disposed on at least one cell array (120) of the powerpack (102).

7. The BMS (100) as claimed in claim 1, wherein the processing unit (110) is configured to receive input from the voltage sensing module (104), the current sensing module (106), and/or the temperature sensing module (108).

8. The BMS (100) as claimed in claim 7, wherein the processing unit (110) is configured to identify at least one fault associated with the voltage sensing module (104), the current sensing module (106), and/or the temperature sensing module (108).

9. The BMS (100) as claimed in claim 8, wherein the processing unit (110) is configured to electrically isolate the voltage sensing module (104), the current sensing module (106), and/or the temperature sensing module (108), based on the identified fault, by operating the plurality of switching devices (116).