Description:TECHNICAL FIELD
[0001] The present disclosure relates to battery management. In particular, the present disclosure relates to a system and a method for protecting a battery pack against overcurrent during charging and discharging conditions of the battery pack, thereby enhancing safety and prolonging the lifespan of the battery pack.

BACKGROUND
[0002] In a battery system, various short-circuit scenarios can occur resulting in a current flow in a battery pack dependent on the resistance of an external short path. These scenarios are categorised into two types such as hard shorts and soft shorts. In case of hard shorts exceptionally high currents are exhibited, demanding an action to prevent potential damage to the components within the battery pack. In case of soft shorts high currents are also involved. The response time for both hard shorts and soft shorts must be within milliseconds to avoid the risk of damage to the components. In these scenarios, currents can surge to thousands of amps, depending on the severity of the short circuit and the configuration of the battery pack.
[0003] The consequences of short-circuit scenarios extend beyond immediate damage. This can harm various components within the battery pack, including cells, Battery Management System (BMS) circuitry, series interconnections, and power cables. The severity of this damage can escalate to the extent of causing fire within the battery pack, potentially resulting in fatal accidents. Therefore, protection mechanisms must respond rapidly, ideally within milliseconds, to prevent damage in the battery pack.
[0004] During over current scenarios, currents exceed normal operating levels of the battery pack. Although these currents exceed the typical operating range, they do not reach the extreme levels associated with short circuits, thus posing a lower risk of causing fatal accidents. Such overcurrent scenarios can arise from various sources, including damage or faults in a power path or at a load end of the BMS circuitry. The currents generated in these scenarios result in the heating of the cells and components in the power path, potentially leading to damage or degradation of the overall performance and lifespan of the battery pack. Moreover, if these currents persist for prolonged durations, there is a risk of fire occurring within both the battery pack and the BMS circuitry. To mitigate these risks, protection mechanisms must be designed to respond swiftly, typically within a few seconds, depending on the magnitude of current flow. By implementing effective protection measures, the potential damage and hazards associated with over-current scenarios can be minimized, ensuring the safety and longevity of the battery pack.
[0005] Therefore, there is a need to address the above-mentioned drawbacks, along with any other shortcomings, or at the very least, to provide a viable alternative system and method.

OBJECTS OF THE PRESENT DISCLOSURE
[0006] A general object of the present disclosure relates to an efficient and a reliable system and method that obviates the above-mentioned limitations of existing systems and methods.
[0007] An object of the present disclosure relates to a system and a method for protecting a battery pack against overcurrent by disconnecting a switch when a magnitude of a current flow being in a first predetermined threshold or being in a second predetermined threshold, thereby enhancing safety and prolonging battery lifespan.
[0008] Another object of the present disclosure relates to a system and a method for tripping fuses if a magnitude of a current flow reaches a third predetermined threshold, thereby preventing a battery pack against overcurrent and short-circuit scenarios.

SUMMARY
[0009] Aspects of the disclosure relate to battery management. In particular, the present disclosure relates to a system and a method for protecting a battery pack against overcurrent during charging and discharging conditions of the battery pack, thereby enhancing safety and prolonging lifespan of the battery pack.
[0010] In an aspect, the present disclosure relates to a method of overcurrent protection in a battery pack. The method may include measuring a current flow through the battery pack associated with a system and detecting that a magnitude of a current flow through the battery pack is within a predefined range. Further, the method may include performing one of: disconnecting a switch associated with the system if the magnitude of the current flow being in a first predetermined threshold of the predefined range or being in a second predetermined threshold of the predefined range or tripping one or more fuses associated with the system if the magnitude of the current flow reaches a third predetermined threshold of the predefined range.
[0011] In an embodiment, for measuring the current flow through the battery pack, the method may include filtering noises in a current sensing path configured between the battery pack and an external power source for measuring the current flow.
[0012] In an embodiment, for disconnecting the switch if the magnitude of the current flow being in the first predetermined threshold, the method may include detecting that the current flow exceeds a constant predefined value using a microcontroller associated with the system and detecting that the current flow reaches the first predetermined threshold. Further, the method may include determining that the current flow is being in the first predetermined threshold for a first predefined time period
[0013] In an embodiment, for disconnecting the switch if the magnitude of the current flow being in the first predetermined threshold, the method may include transmitting a control signal to the switch for disconnecting the current flow through the battery pack using the microcontroller.
[0014] In an embodiment, for disconnecting the switch if the magnitude of the current flow being in the second predetermined threshold, the method may include detecting that the current flow through the battery pack reaches the second predetermined threshold using a control unit associated with the system and determining that the current flow being in the second predetermined threshold for a second predefined time period. Further, the method may include triggering the switch for disconnecting the current flow through the battery pack in response to the current flow being in the second predetermined threshold for the second predefined time period.
[0015] In an embodiment, the method may include tuning the first predefined time period and the second predefined time period based on a tolerance level of the battery pack, the microcontroller, and the control unit with respect to the magnitude of the current flow being in the first predefined threshold and being in the second predefined threshold.
[0016] In an embodiment, the method may include tuning the first predefined time period and the second predefined time period based on a frequency of occurrence of the magnitude of the current flow reaching the first predetermined threshold and the second predetermined threshold.
[0017] In an embodiment, the method may include positioning the switch between the battery pack and the external power source.
[0018] In an embodiment, the method may include any one of: positioning each of the one or more fuses in parallel between the battery pack and an external power source or positioning each of the one or more fuses in parallel and configured with each series connection of a plurality of cells of the battery pack.
[0019] In an embodiment, the method may include placing each of the one or more fuses with a predefined spacing between each of the one or more fuses.
[0020] In an embodiment, for positioning each of the one or more fuses in parallel between the battery pack and an external power source, the method may include aligning a first fuse of the one or more fuses corresponding to the switch with two sets of fuses positioned adjacent to the switch and parallel to the first fuse, wherein the predefined spacing between each fuse in both sets being equivalent.
[0021] In an embodiment, the method may include preconfiguring a tolerance level for each of the one or more fuses in a low level compared to a tolerance level of the battery pack and the plurality of cells with respect to the magnitude of the current flow reaching the third predetermined threshold.
[0022] In an embodiment, the method may include tripping the one or more fuses if a microcontroller and a control unit is in a disable state when the magnitude of the current flow reaching the third predetermined threshold.
[0023] In another aspect, the present disclosure relates to a system of overcurrent protection in a battery pack. The system is configured to measure a current flow through the battery pack and detect that a magnitude of a current flow through the battery pack is within a predefined range. Further, the system is configured to perform one of: disconnect a switch if the magnitude of the current flow being in a first predetermined threshold of the predefined range or being in a second predetermined threshold of the predefined range or trip one or more fuses if the magnitude of the current flow reaches a third predetermined threshold of the predefined range.
[0024] In an embodiment, the system may be configured to filter noises in a current sensing path configured between the battery pack and an external power source for measuring the current flow.
[0025] In an embodiment, the system may be configured to detect that the current flow exceeds a constant predefined value using a microcontroller associated with the system and detect that the current flow reaches the first predetermined threshold. Further, the system may be configured to determine that the current flow is being in the first predetermined threshold for a first predefined time period.
[0026] In an embodiment, the system may be configured to transmit a control signal to the switch for disconnecting the current flow through the battery pack using the microcontroller.
[0027] In an embodiment, the system may be configured to detect that the current flow through the battery pack reaches the second predetermined threshold using a control unit associated with the system and determine that the current flow being in the second predetermined threshold for a second predefined time period. Further, the system may be configured to trigger the switch for disconnecting the current flow through the battery pack in response to the current flow being in the second predetermined threshold for the second predefined time period.
[0028] In an embodiment, the system may be configured to tune the first predefined time period and the second predefined time period based on a tolerance level of the battery pack, the microcontroller, and the control unit with respect to the magnitude of the current flow being in the first predefined threshold and being in the second predefined threshold.
[0029] In an embodiment, the system may be configured to tune the first predefined time period and the second predefined time period based on a frequency of occurrence of the magnitude of the current flow reaching the first predetermined threshold and the second predetermined threshold.
[0030] In an embodiment, the switch may be positioned between the battery pack and the external power source.
[0031] In an embodiment, each of the one or more fuses may be positioned in parallel between the battery pack and an external power source or each of the one or more fuses may be positioned in parallel and configured with each series connection of a plurality of cells of the battery pack.
[0032] In an embodiment, the one or more fuses may be placed with a predefined spacing between each of the one or more fuses.
[0033] In an embodiment, a first fuse of the one or more fuses may be aligned corresponding to the switch with two sets of fuses positioned adjacent to the switch and parallel to the first fuse, where the predefined spacing between each fuse in both sets being equivalent
[0034] In an embodiment, a tolerance level for each of the one or more fuses may be preconfigured with a low level compared to a tolerance level of the battery pack and the plurality of cells with respect to the magnitude of the current flow reaching the third predetermined threshold.
[0035] In an embodiment, the one or more fuses may be tripped if a microcontroller and a control unit are in a disable state when the magnitude of the current flow reaches the third predetermined threshold.
[0036] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0038] FIG. 1 illustrates a schematic view of an Electric Vehicle (EV), in accordance with embodiments of the present disclosure.
[0039] FIG. 2 illustrates a schematic representation of a system for protecting a battery pack from overcurrent, in accordance with embodiments of the present disclosure.
[0040] FIG. 3 illustrates a graphical representation related to enabling three modes of protection with respect to a magnitude of a current flow reaching a point within a predefined range, in accordance with embodiments of the present disclosure.
[0041] FIG. 4 illustrates a flow chart of a method for disconnecting a switch to protect the battery pack from the overcurrent, in accordance with embodiments of the present disclosure.
[0042] FIG. 5 illustrates a flow chart of a method for protecting the battery pack from the overcurrent, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION
[0043] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosures as defined by the appended claims.
[0044] For the purpose of understanding of the principles of the present disclosure, reference will now be made to the various embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the present disclosure is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the present disclosure as illustrated therein being contemplated as would normally occur to one skilled in the art to which the present disclosure relates.
[0045] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the present disclosure and are not intended to be restrictive thereof.
[0046] Whether or not a certain feature or element was limited to being used only once, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, “there needs to be one or more” or “one or more elements is required.”
[0047] Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements of the present disclosure. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.
[0048] Use of the phrases and/or terms including, but not limited to, “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment,” “additional embodiment” or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.
[0049] Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the proposed disclosure.
[0050] The terms “comprise,” “comprising,” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by “comprises... a” does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.
[0051] Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.
[0052] For the sake of clarity, the first digit of a reference numeral of each component of the present disclosure is indicative of the Figure number, in which the corresponding component is shown. For example, reference numerals starting with digit “1” are shown at least in Figure 1. Similarly, reference numerals starting with digit “2” are shown at least in Figure 2.
[0053] An Electric Vehicle (EV) or a battery powered vehicle including, and not limited to two-wheelers such as scooters, mopeds, motorbikes/motorcycles; three-wheelers such as auto-rickshaws, four-wheelers such as cars and other Light Commercial Vehicles (LCVs) and Heavy Commercial Vehicles (HCVs) primarily work on the principle of driving an electric motor using the power from the batteries provided in the EV. Furthermore, the electric vehicle may have at least one wheel which is electrically powered to traverse such a vehicle. The term ‘wheel’ may be referred to any ground-engaging member which allows traversal of the electric vehicle over a path. The types of EVs include Battery Electric Vehicle (BEV), Hybrid Electric Vehicle (HEV) and Range Extended Electric Vehicle. However, the subsequent paragraphs pertain to the different elements of a Battery Electric Vehicle (BEV).
[0054] FIG. 1 illustrates a schematic view of an Electric Vehicle (EV), in accordance with embodiments of the present disclosure.
[0055] In construction, an EV (10) typically comprises a battery or battery pack (12) enclosed within a battery casing and includes a Battery Management System (BMS), an on-board charger (14), a Motor Controller Unit (MCU), an electric motor (16) and an electric transmission system (18). The primary function of the above-mentioned elements is detailed in the subsequent paragraphs: The battery of an EV (10) (also known as Electric Vehicle Battery (EVB) or traction battery) is re-chargeable in nature and is the primary source of energy required for the operation of the EV, wherein the battery (12) is typically charged using the electric current taken from the grid through a charging infrastructure (20). The battery may be charged using Alternating Current (AC) or Direct Current (DC), wherein in case of AC input, the on-board charger (14) converts the AC signal to DC signal after which the DC signal is transmitted to the battery via the BMS. However, in case of DC charging, the on-board charger (14) is bypassed, and the current is transmitted directly to the battery via the BMS.
[0056] The battery (12) is made up of a plurality of cells which are grouped into a plurality of modules in a manner in which the temperature difference between the cells does not exceed 5 degrees Celsius. The terms “battery”, “cell”, and “battery cell” may be used interchangeably and may refer to any of a variety of different rechargeable cell compositions and configurations including, but not limited to, lithium-ion (e.g., lithium iron phosphate, lithium cobalt oxide, other lithium metal oxides, etc.), lithium-ion polymer, nickel metal hydride, nickel cadmium, nickel hydrogen, nickel-zinc, silver zinc, or other battery type/configuration. The term “battery pack” as used herein may be referred to multiple individual batteries enclosed within a single structure or multi-piece structure. The individual batteries may be electrically interconnected to achieve a desired voltage and capacity for a desired application. The Battery Management System (BMS) is an electronic system whose primary function is to ensure that the battery (12) is operating safely and efficiently. The BMS continuously monitors different parameters of the battery such as temperature, voltage, current and so on, and communicates these parameters to the Electronic Control Unit (ECU) and the Motor Controller Unit (MCU) in the EV using a plurality of protocols including and not limited to Controller Area Network (CAN) bus protocol which facilitates the communication between the ECU/MCU and other peripheral elements of the EV (10) without the requirement of a host computer.
[0057] The MCU primarily controls/regulates the operation of the electric motor based on the signal transmitted from the vehicle battery, wherein the primary functions of the MCU include starting of the electric motor (16), stopping the electric motor (16), controlling the speed of the electric motor (16), enabling the vehicle to move in the reverse direction and protect the electric motor (16) from premature wear and tear. The primary function of the electric motor (16) is to convert electrical energy into mechanical energy, wherein the converted mechanical energy is subsequently transferred to the transmission system of the EV (10) to facilitate movement of the EV (10). Additionally, the electric motor (16) also acts as a generator during regenerative braking (i.e., kinetic energy generated during vehicle braking/deceleration is converted into potential energy and stored in the battery of the EV (10)). The types of motors generally employed in EVs include, but are not limited to DC series motor, Brushless DC motor (also known as BLDC motors), Permanent Magnet Synchronous Motor (PMSM), Three Phase AC Induction Motors and Switched Reluctance Motors (SRM).
[0058] The transmission system (18) of the EV (10) facilitates the transfer of the generated mechanical energy by the electric motor (16) to the wheels (22a, 22b) of the EV (10). Generally, the transmission systems (18) used in EVs include single speed transmission system and multi-speed (i.e., two-speed) transmission system, wherein the single speed transmission system comprises a single gear pair whereby the EV (10) is maintained at a constant speed. However, the multi-speed/two-speed transmission system comprises a compound planetary gear system with a double pinion planetary gear set and a single pinion planetary gear set thereby resulting in two different gear ratios which facilitates higher torque and vehicle speed.
[0059] In one embodiment, all data pertaining to the EV (10) and/or charging infrastructure (20) are collected and processed using a remote server (known as cloud) (24), wherein the processed data is indicated to the rider/driver of the EV (10) through a display unit present in the dashboard (26) of the EV (10). In an embodiment, the display unit may be an interactive display unit. In another embodiment, the display unit may be a non-interactive display unit.
[0060] Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.
[0061] For the sake of clarity, the first digit of a reference numeral of each component of the present disclosure is indicative of the Figure number, in which the corresponding component is shown. For example, reference numerals starting with digit “1” are shown at least in Figure 1. Similarly, reference numerals starting with digit “2” are shown at least in Figure 2.
[0062] Embodiments of the present disclosure relate to battery management. In particular, the present disclosure relates to a system and a method for protecting a battery pack against overcurrent during charging and discharging conditions of the battery pack, thereby enhancing safety and prolonging lifespan of the battery pack.
[0063] Various embodiments of the present disclosure will be explained in detail with respect to FIGs. 2 to 5.
[0064] FIG. 2 illustrates a schematic representation of a system (200) for protecting a battery pack (204) from overcurrent, in accordance with embodiments of the present disclosure.
[0065] Referring to FIG. 2, the system (200) may include the battery pack (204) and a BMS (202). The battery pack (204) may include a plurality of cells (204A). The BMS (202) may include various components such as, but not limited to a resistor (202A), a switch (202B), fuses (202C), and the like. In the battery pack (204), the plurality of cells (204A) may function as energy storage units, storing electrical energy received from the external power source. In an embodiment, the resistor (202A) within the BMS (202) may sense the charging and discharging the current flowing through the battery pack (204). In an embodiment, the fuses (202C) may act as a protective device that interrupts the system (200) in an event of short circuit scenario to prevent damage to the battery pack (204) and associated components. In an embodiment, the switch (202B) may be positioned after the fuses (202C), where the switch (202B) may be configured to enable and disable the current flow within the system (200) as per operational requirements. Alternatively, the switch (202B) may be positioned before the fuses (202C) or the switch (202B) may be positioned after the fuses (202C). Additionally, the BMS (202) may interface with the external power source via B+ and B- terminals to receive/deliver power. In an embodiment, B- may be connected to the fuse and provide a pathway for the current interruption in case faults occur in the system (200) and B+ may be connected to the battery pack (204), thereby establishing a transmission of power from the external source to the plurality of cells (204A) within the battery pack (204). In an embodiment, B- may be connected to the fuse and provide a pathway for the current interruption in case faults occur in the system (200) and B+ may be connected to the battery pack (204), thereby establishing a transmission of power from the battery pack (204) to a load.
[0066] In an embodiment, B- may be connected to the battery pack (204) and B+ may be connected to the fuse and provide a pathway for the current interruption in case faults occur in the system (200) and B+ may be connected to the battery pack (204), thereby allowing current flow through the battery pack (204). In an embodiment, the current flow through the battery pack (204) may refer to two scenarios. In a first scenario, the current flows into the battery pack (204) from the external power source. This may occur during the power is being supplied to the battery pack (204) for charging. In a second scenario, various loads such as, but not limited to, indicators, headlights, and other peripherals associated with the vehicle (10) are connected to the battery pack (204) to draw the necessary current from the battery pack (204) for its operations.
[0067] In an embodiment, the system (200) may include a microcontroller and a control unit for measuring a current flow through the battery pack (204). In exemplary embodiments, the system (200) may be configured to filter noises in a current sensing path using a Resistor-Capacitor (RC) filter for measuring the current flow. In an embodiment, the system (200) may detect whether a magnitude of the current flow through the battery pack (204) is within a predefined range or not using the microcontroller and the control unit. If the magnitude of the current flow through the battery pack (204) is within the predefined range, the system (200) detects whether the magnitude of the current flow is being in a first predetermined threshold of the predefined range or being in a second predetermined threshold of the predefined range.
[0068] In an embodiment, if the system (200) detects that the magnitude of the current flow is in the first predetermined threshold (e.g., an overcurrent scenario), the microcontroller may transmit a control signal to the switch (202B) to disconnect the current flow through the battery pack (204). For example, the first predetermined threshold may be set at 200 amperes with a time window of 5 seconds (e.g., a first predefined time period). For example, if the system (200) detects that the magnitude of the current flow persists at 500 amperes at the time window of 2 seconds (e.g., being in the first predetermined threshold), the microcontroller may transmit the control signal to the switch (202B) to disconnect the current flow through the battery pack (204). In exemplary embodiments, the microcontroller may trigger the switch (202B) to open to disconnect the current flow between the external source and the system (200).
[0069] In this scenario, the magnitude of the current flow is relatively lower, distinguishing the magnitude of the current flow from others. In an embodiment, these lower currents typically do not cause immediate damage to the battery pack (204) or BMS components (e.g., the components associated with the BMS (202)). However, prolonged exposure to these currents may result in component degradation due to overheating. Therefore, the required response time in such cases may be slightly longer, spanning a few seconds. This broader timeframe may be accommodated using the microprocessor or the microcontroller, enabling the implementation of protection mechanisms through software algorithms, thus reducing costs. The RC filters may be integrated into the current sensing path or circuit to prioritize noise filtering. In an embodiment, the measured currents may be relayed to a firmware. When the magnitude of the current flow surpasses the first predetermined threshold, as programmed in an algorithm, for a specified duration (e.g., the first predefined time period), the firmware has the capability to initiate the shutdown of the BMS switches (e.g., 202B), effectively blocking current flow in the power path. The timing thresholds (e.g., the first predetermined threshold) for this protection mechanism may be fine-tuned based on the severity of the impact of these current flows on the battery pack (204) and the BMS components, as well as the frequency of occurrence of such current levels.
[0070] Similarly, if the system (200) detects whether the current flow through the battery pack (204) reaches the second predetermined threshold or not. If the current flow through the battery pack (204) reaches the second predetermined threshold, the system (200) may determine whether the current flow through the battery pack (204) being in the second predetermined threshold for a second predefined time period or not. If the current flow through the battery pack (204) is in the second predetermined threshold for a second predefined time period (e.g., soft shorts occurred) the control unit may trigger the switch (202B) to open to disconnect the current flow through the battery pack (204). For example, the second predetermined threshold may be set at 600 amperes with a time window of 3 milliseconds (e.g., the second predefined time period). For example, if the system (200) detects that the magnitude of the current flow persists at 600 amperes for the time window of 3 milliseconds (e.g., being in the second predetermined threshold), the control unit may trigger the switch (202B) to open to disconnect the current flow through the battery pack (204). In exemplary embodiments, the switch (202B) may be positioned between the battery pack (204) and the external power source, as the switch (202B) is integrated within the BMS (202).
[0071] In soft short scenarios, the current, though lower than in hard shorts, still poses a risk of causing substantial damage to both the plurality of cells (204A) and the BMS components over a slightly extended duration. The action time for these shorts can be very short, and hence the hardware-enabled protection is used. This protection mechanism may involve the current sensing path of the BMS (202). In an embodiment, a hardware-enabled current limit is given to a comparator circuit associated with the BMS (202) as a threshold (e.g., the second predetermined threshold). The comparator may check whether the magnitude of the current flow being in the second predetermined threshold or not. When the sensed current of the battery pack (204) crosses the second predetermined threshold, the control unit may trigger the switches (e.g., 202B) in the BMS (202) to be opened, and the current flow in a power path is blocked.
[0072] In an embodiment, the RC filter may be used to filter noise in the current sensing path to improve the accuracy of current measurements. The short circuit detection and tripping mechanism may act very quickly in order to protect the battery pack (204) and the BMS (202). Thus, the RC circuit may be tuned very finely in order to achieve a balance between the noise in the system (200) and the action time of the protection mechanism. To enhance system stability, the process of verifying the threshold (e.g., the second predetermined threshold) breach is iterated multiple times before flagging the occurrence of a short circuit fault. In an embodiment, once the fault is detected, the power path may be disconnected, and the current flow through the battery pack (204) is blocked. This entire process may happen within a few milliseconds, and this timing (e.g., the second predefined time period) may be tuned depending on the time to failure of the battery pack (204) and the BMS components at the soft short current levels.
[0073] In an embodiment, if the magnitude of the current flow reaches a third predetermined threshold of the predefined range (e.g. if the hard shorts occur) the fuses (202C) may trip or blow to protect the battery pack (204) from the hard sort. In an embodiment, a tolerance level for the fuses (202C) may be preconfigured with a low level compared to a tolerance level of the battery pack (204) and the plurality of cells (204A) with respect to the magnitude of the current flow reaching the third predetermined threshold. For example, if the tolerance level for the battery pack (204) and the plurality of cells (204A) may be configured at 1500 amperes for few microseconds, the tolerance level for the fuses (202C) may be set at 1000 amperes for few microseconds, with respect to the magnitude of the current flow reaching the third predetermined threshold. This third predetermined threshold may be set at 1000 amperes. If the magnitude of the current flow reaches or exceeds 1000 amperes (e.g., reaches the third predetermined threshold), the fuses (202C) may trip to prevent damage to the battery pack (204).
[0074] In an embodiment, the fuses (202C) may be positioned between the battery pack (204) and the external power source/load. In exemplary embodiments, the fuses (202C) may be positioned in parallel and configured with each series connection of the plurality of cells (204A) of the battery pack (204). In exemplary embodiments, each of the fuses (202C) may be placed with a predefined spacing between each fuse. In an embodiment, the fuse stacking must be symmetrical about the point of current entry. In an alternate embodiment, the fuses may be placed equidistant from each other. In an embodiment, if the microcontroller and the control unit are in a disable state due to some factors such as malfunction or system failure, the fuses (202C) may be tripped when the magnitude of the current flow reaches the third predetermined threshold. For example, where the BMS (202) has malfunctioned due to certain issues and the hardware-enabled protection circuit has been damaged, the fuses (202C) may serve as an alternative protection mechanism for soft shorts. In this case, the fuses (202C) may blow in time to safeguard the battery pack (204) from potential damage.
[0075] Basically, the fuses are classified into two types such as fast-acting fuses and slow-acting fuses. The fast-acting fuses take a short time to blow completely, and similarly, the slow-acting fuses take a long time to blow completely. For an entire battery pack, a single fuse with a high current rating is required, which tends to be costly and large in size. The large size of these fuses presents mounting and assembly challenges. Additionally, cheaper pack fuses are often slow-acting, leading to longer fuse blow times that can result in damage or degradation of Field Effect Transistors (FETs)/ contactors of the BMS (202) or the plurality of cells (204A), potentially causing a fire. To address these challenges, multiple fast-acting fuses (202C) with lower current ratings may be connected in parallel to create a fast-acting pack fuse. In an embodiment, these fuses (202C) may either emulate the fast-acting pack fuse when used as a fuse stack or serve as individual series connections for cells (204A), acting as cell-level fuses (202C). In an embodiment, the rating (e.g., the tolerance level) of cell-level fuses (202C) may be determined by the current carrying capacity of each series row of cells (204A). In an embodiment, the selection of an emulated pack fuse may depend on various factors, including design constraints, the form factor, and the number of fuses that can fit into the BMS (202). In an embodiment, the resistance of these fuses may result in their own I2R losses, leading to the heating of neighbouring components on the BMS (202), and potentially affecting the regular functionality of the BMS (202). The acceptable temperature rise on other BMS components determines the current rating of each individual fuse and the number of fuses that can be used in parallel.
[0076] Basically, the behaviour of the fuses may degrade over time due to the rise in temperature resulting from nearby BMS components. Characterizing this degradation and selecting a fuse with an appropriate current rating is imperative to ensure the fuse does not blow prematurely during regular operation. To overcome this situation, modifications to the design of the BMS (202) or the corresponding Printed Circuit Board (PCB) are required to achieve optimal heat dissipation. This optimization is determined by factors such as heat dissipation away from the fuse and BMS circuitry during normal pack operation, as well as heat dissipation from the fuse to reduce degradation over its lifespan. Moreover, the PCB design may introduce a skew in the current flow through each individual fuse. This skew may cause one fuse to experience a higher current than others, leading to premature blowing. However, this blowing of one fuse triggers a rapid increase in the current flowing through the other fuses, resulting in their quick succession blowing. In an embodiment, the predefined spacing may be provided between fuses (202C) to ensure that the current skew does not impact the fuse stack during normal battery pack (204) operation. This may ensure the effective functioning of a fuse protection system.
[0077] FIG. 3 illustrates a graphical representation (300) related to enabling three modes of protection with respect to the magnitude of the current flow reaching a point within a predefined range, in accordance with embodiments of the present disclosure.
[0078] Referring to FIG. 3, in the graph representation (300), I2t may represent the cumulative energy dissipation over time for different components associated with the system (200). The I2t may represent the amount of energy passing through the component over a specific duration, taking into account both the magnitude of the current (I) and the time (t). The I2t curve or the point for each component provides insight into the ability of the component to handle the current flow and the associated thermal stress over time. In exemplary embodiments, the I2t curve of the BMS switches (e.g., the switch (202B) integrated in the BMS (202)) may represent the relationship between the magnitude of the current flowing through the BMS (202) and the time it persists, indicating the cumulative effect of current on the BMS (202) over time. In exemplary embodiments, the I2t curve of the fuses (202C) may represent a blow time of the fuses (202C) that varies with different levels of current flow, providing insights into the protective function against overcurrent scenarios. In exemplary embodiments, the I2t spread of the Li-Ion cells (204A) used in the battery pack (204) at various State of Charge (SoC) points may represent the I2t spread of the lithium-ion (Li-Ion) cells (e.g., the plurality of cells (204A)) within the battery pack (204) at different State-of-Charge (SoC) points. This illustration demonstrates the behaviour of the plurality of cells (204A) in response to current varies depending on their state of charge. In exemplary embodiments, the I2t point of the hardware (e.g., the control unit)-enabled protection may represent a threshold (e.g., the second predetermined threshold) at which the protection mechanism (e.g., the control unit) intervenes to safeguard the battery system (e.g., 200) from overcurrent or short-circuit conditions. In exemplary embodiments, the I2t point of the software (e.g., the microcontroller)-enabled protection may represent a threshold (e.g., the first predetermined threshold) at which the software (e.g., the microcontroller)-based protection system triggers its response to mitigate potential risks associated with overcurrent situations. In exemplary embodiments, the I2t curve of the normal operating currents may represent the normal operating currents of the battery system (200). This may serve as a reference to compare against the protective thresholds and responses indicated by the other elements in the graph.
[0079] FIG. 3 illustrates three modes to protect the system (200) from the overcurrent. In the graphical representation, each mode of protection may fall into separate buckets such as bucket 1, bucket 2, and bucket 3. In exemplary embodiments, bucket 1 to bucket 3 may correspond to the predefined range. In a first mode (e.g., overcurrent scenario), when the magnitude of the current flow reaches the first predetermined threshold which is represented as a cross symbol in bucket 3, the microcontroller (e.g., the software-enabled protection) may transmit the control signal to trigger the switch (202B) to open to disconnect the current flowing through the battery pack (204). In a second mode (e.g., soft shorts), when the magnitude of the current flow reaches the second predetermined threshold which is represented as a square symbol in bucket 2, the control unit (e.g., the hardware-enabled protection) may trigger the switch (202B) to open to disconnect the current flowing through the battery pack (204). In a third mode (e.g., the hard shorts), when the magnitude of the current flow reaches the third predetermined threshold which is represented as a continuous line reaching bucket 1, the fuses (202C) may trip to disconnect the current flowing through the battery pack (204).
[0080] For example, in the third mode, characterized by the hard short with low resistance, the current drawn from the battery pack (204) surpasses 1000 amperes. Here, the fuses (202C) may take precedence, blowing before the hardware or software protections engage, as the fuses (202C) react faster to high currents based on the I2t curve in the hard short region (bucket 1). In an embodiment, rapid heating of the fuses (202C) may occur at such intense currents, prompting the fuses (202C) to blow and avoid damage to the battery pack (204) prior to the activation of the other two protections.
[0081] For example, in the second mode, when encountering the soft short (high-resistance short) and the current drawn from the battery pack (204) is, for instance, around 600 amperes, a distinct behaviour may be observed. Here, the fuses (202C) may exhibit a slightly delayed response in blowing due to the time required for lower currents to sufficiently heat the fuses (202C). Consequently, the software-enabled protections take longer time to respond. Consequently, the hardware-enabled protection mechanism may be activated before either the fuse or software-enabled protections engage, as the hardware-enabled protection may operate more rapidly than the latter two at these current levels, as determined by the I2t curve in the soft short region (bucket 2).
[0082] For example, in the first mode, the scenario may involve an overcurrent flowing through the battery pack (204), typically caused by a very high resistance short or malfunction in the power path. During this situation, the current flowing through the battery pack (204) exceeds the normal operating currents (e.g., reaches the first predetermined threshold) by a certain margin. In such cases, the software-enabled protections may trigger, as the fuse does not heat up sufficiently to blow at these lower currents, and the hardware-enabled protection limits may be adjusted to account for higher currents.
[0083] The selection of current rating fuses is essential to ensure that the I2t curve of the fuse remains below the I2t curves of all components within the battery pack (204) and the BMS (202) that require protection, including BMS FETs and cells (204A). This criterion may ensure that the fuse blows before any of these components fail. In an embodiment, the I2t curve of the BMS FETs may be determined using the parameters provided in their datasheets. Similarly, the I2t curve of the cells (204A) may be derived through cell-level tests involving shorting with various short impedances, followed by considering the corresponding time to failure of the cell. Furthermore, the I2t curve of the fuse must remain below that of other components within the battery pack (204) and the BMS (202). However, that curve may still be higher than the peak operating currents of the battery pack (204) to avoid affecting normal operation. This balancing act may ensure effective protection against overcurrent scenarios while maintaining the functionality of the battery pack (204) and the BMS components.
[0084] FIG. 4 illustrates a flow chart of a method (400) for disconnecting the switch (202B) to protect the battery pack (204) from the overcurrent, in accordance with embodiments of the present disclosure.
[0085] Referring to FIG. 4, at (402), the method (400) may include detecting whether the current flow exists or not using the microcontroller. If the current flow exists, the method (400) may include detecting whether the magnitude of the current flow reaches a predefined limit (e.g., the first predetermined threshold) or not as represented in (404). If the magnitude of the current flow reaches the first predetermined threshold, the method (400) may include determining whether the magnitude of the current flow is above the first predetermined threshold for the first predefined time period (e.g., the magnitude of the current flow is above the first predetermined threshold) or not as represented in (406). If the magnitude of the current flow is above the first predetermined threshold for the first predefined time period (e.g., x seconds), the microcontroller (e.g., the software-enabled protection) may raise a fault and transmit the control signal to disconnect the corresponding BMS switch (202B) to stop the current flow through the battery pack (204) as represented in (408).
[0086] In an embodiment, the system (200) may be configured to tune the second predefined time period based on the tolerance level of the battery pack (204), BMS switch, and the control unit with respect to the magnitude of the current flow above the second predefined threshold. For example, if the battery pack (204), the control unit, and other components in the system (200) may tolerate up to 800 amperes for 1 second, the second predefined time may set as 5 milliseconds based on the tolerance level of the battery pack (204), the control unit, and other components in the system (200). However, if the tolerance level of the battery pack (204), the control unit, and other components in the system (200) is reduced due to lifespan degradation, then the system (200) may tune the second predefined time period as 3 milliseconds, so that the system (200) may protect the battery pack (204), the control unit, and other component in the system (200) before affected by overcurrent.
[0087] In an embodiment, the first predetermined threshold and the first predefined time period are set based on the normal operating current flowing through the battery pack 204.
[0088] In an embodiment, the system (200) may be configured to tune the first predefined time period and the second predefined time period based on a frequency of occurrence of the magnitude of the current flow reaching the first predetermined threshold and the second predetermined threshold. For example, if the first predefined time period is set to 6 seconds, the second predefined time period is set to 8 seconds and if the system (200) detects that the magnitude of the current flow reaches the first predetermined threshold frequently within a short duration, the system (200) may reduce the first predefined time period to 3 seconds to provide quicker protection against overcurrent events. Similarly, if the magnitude of the current flow reaches the second predetermined threshold more frequently within the short duration, the system (200) may decrease the second predefined time period to 5 seconds.
[0089] FIG. 5 illustrates a flow chart of a method (500) for protecting the battery pack (204) from the overcurrent, in accordance with embodiments of the present disclosure.
[0090] Referring to FIG. 5, at (502), the method (500) may include measuring the current flow through the battery pack (204) associated with the system (200). In an embodiment, the method (500) may include filtering noises in the current sensing path configured between the battery pack (204) and the external power source for measuring the current flow. At (504), the method (500) may include detecting that the magnitude of the current flow through the battery pack (204) is within the predefined range.
[0091] At (506A), the method (500) may include disconnecting the switch (202B) associated with the system (200) if the magnitude of the current flow being in the first predetermined threshold of the predefined range or being in the second predetermined threshold of the predefined range. In an embodiment, the method (500) may include detecting that the current flow exceeds the constant predefined value using the microcontroller associated with the system (200) and detecting that the current flow reaches the first predetermined threshold based on the detection of the current flow exceeds the constant predefined value. In an embodiment, the method (500) may include determining that the current flow is being in the first predetermined threshold for the first predefined time period. In an embodiment, the method (500) may include transmitting a control signal to the switch (202B) for disconnecting the current flow through the battery pack (204) using the microcontroller.
[0092] At (506B), the method (500) may include tripping one or more fuses (202C) associated with the system (200) if the magnitude of the current flow reaches a third predetermined threshold of the predefined range. In an embodiment, the method (500) may include detecting that the current flow through the battery pack (204) reaches the second predetermined threshold using the control unit associated with the system (200) and determining that the current flow being in the second predetermined threshold for the second predefined time period. In an embodiment, the method (500) may include triggering the switch (202B) for disconnecting the current flow through the battery pack (204).
[0093] In an embodiment, the method (500) may include tuning the first predefined time period and the second predefined time period based on the tolerance level of the battery pack (204), the microcontroller, and the control unit with respect to the magnitude of the current flow being in the first predefined threshold and being in the second predefined threshold. In an embodiment, the method (500) may include tuning the first predefined time period and the second predefined time period based on the frequency of occurrence of the magnitude of the current flow reaching the first predetermined threshold and the second predetermined threshold.
[0094] In an embodiment, the method (500) may include positioning the switch (202B) between the battery pack (204) and the external power source. In an embodiment, the method (500) may include positioning each of the one or more fuses (202C) in parallel between the battery pack (204) and the external power source. In exemplary embodiments, the method (500) may include positioning each of the one or more fuses (202C) in parallel and configured with each series connection of the plurality of cells (204A) of the battery pack (204).
[0095] In an embodiment, the method (500) may include placing each of the one or more fuses (202C) with the predefined spacing between each of the one or more fuses (202C). In an embodiment, the method (500) may include aligning a first fuse of the one or more fuses (202C) corresponding to the switch (202B) with two sets of fuses (202C) positioned adjacent to the switch (202B) and parallel to the first fuse, wherein the predefined spacing between each fuse in both sets is equivalent.
[0096] In an embodiment, the method (500) may include preconfiguring the tolerance level for each of the one or more fuses (202C) in the low level compared to the tolerance level of the battery pack (204) and the plurality of cells (204A) with respect to the magnitude of the current flow reaching the third predetermined threshold. In an embodiment, the method (500) may include tripping the one or more fuses (202C) if the microcontroller and the control unit is in the disable state when the magnitude of the current flow reaches the third predetermined threshold.
[0097] In exemplary embodiments, by having a three-modes of protection mechanism that achieves quicker and more accurate overcurrent protection mechanisms across all ranges of current (e.g., within the predefined range), at a much lower cost. This may achieve with a single circuit or algorithm may result in a compromise on either the action time or the accuracy, thus impacting the normal operation of the battery pack (204), the severity of the accidents caused due to overcurrent, and the pack-level degradation caused due to overcurrent. In the present disclosure, the system (200) and the method (500) may depend on the current flowing through the BMS (202), this chemistry-agnostic solution may be tuned and used for all Li-Ion battery packs depending on the application.
[0098] In this application, unless specifically stated otherwise, the use of the singular includes the plural and the use of “or” means “and/or.” Furthermore, use of the terms “including” or “having” is not limiting. Any range described herein will be understood to include the endpoints and all values between the endpoints. Features of the disclosed embodiments may be combined, rearranged, omitted, etc., within the scope of the disclosure to produce additional embodiments. Furthermore, certain features may sometimes be used to advantage without a corresponding use of other features.
[0099] While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The scope of the disclosure is determined by the claims that follow. The disclosure is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the disclosure when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE PRESENT DISCLOSURE
[00100] The present disclosure relates to a system and a method for detecting and responding to overcurrent and short-circuit scenarios to enhance the safety of the battery pack, reducing the risk of damage and potential hazards.
[00101] The present disclosure relates to a system and a method for implementing effective protection mechanisms to prolong the lifespan of the battery pack by preventing excessive stress and damage caused by overcurrent events, thereby optimizing long-term performance.
[00102] The present disclosure relates to a system and a method for protecting against overcurrent events to minimize the need for costly repairs or replacements, resulting in reduced maintenance expenses and downtime for the battery pack.
, Claims:1. A method (500) of overcurrent protection in a battery pack (204), comprising:
measuring (502) a current flow through the battery pack (204) associated with a system (200);
detecting (504) that a magnitude of current flow through the battery pack (204) is within a predefined range; and
performing one of:
disconnecting (506A) a switch (202B) associated with the system (200) if the magnitude of the current flow being in a first predetermined threshold of the predefined range or being in a second predetermined threshold of the predefined range; or
tripping (506B) one or more fuses (202C) associated with the system (200) if the magnitude of the current flow reaches a third predetermined threshold of the predefined range.
2. The method (500) as claimed in claim 1, wherein measuring (502) the current flow through the battery pack (204) comprises:
filtering noises in a current sensing path through the battery pack (204) for measuring the current flow.
3. The method (500) as claimed in claim 2, wherein disconnecting (506A) the switch (202B) if the magnitude of the current flow through the battery pack is in the first predetermined threshold comprises:
detecting that the current flow exceeds a constant predefined value using a microcontroller associated with the system (200);
detecting that the current flow reaches the first predetermined threshold; and
determining that the current flow is being in the first predetermined threshold for a first predefined time period.
4. The method (500) as claimed in claim 3, wherein disconnecting (506A) the switch (202B) if the magnitude of the current flow being in the first predetermined threshold comprises:
transmitting a control signal to the switch (202B) for disconnecting the current flow through the battery pack (204) using the microcontroller.
5. The method (500) as claimed in claim 4, wherein disconnecting (506A) the switch (202B) if the magnitude of the current flow being in the second predetermined threshold comprises:
detecting that the current flow through the battery pack (204) reaches the second predetermined threshold using a control unit associated with the system (200);
determining that the current flow being in the second predetermined threshold for a second predefined time period; and
triggering the switch (202B) for disconnecting the current flow through the battery pack (204) in response to the current flow being in the second predetermined threshold for the second predefined time period.
6. The method (500) as claimed in claim 5, comprising:
tuning the first predefined time period and the second predefined time period based on a tolerance level of the battery pack (204), the microcontroller, and the control unit with respect to the magnitude of the current flow being in the first predefined threshold and being in the second predefined threshold.
7. The method (500) as claimed in claim 6, comprising:
tuning the first predefined time period and the second predefined time period based on a frequency of occurrence of the magnitude of the current flow reaching the first predetermined threshold and the second predetermined threshold.
8. The method (500) as claimed in claim 7, comprising:
positioning the switch (202B) between the battery pack (204) and the external power source.
9. The method (500) as claimed in claim 1, comprising any one of:
positioning each of the one or more fuses (202C) in parallel between the battery pack (204) and an external power source or load; or
positioning each of the one or more fuses (202C) in parallel and configured with each series connection of a plurality of cells (204A) of the battery pack (204).
10. The method (500) as claimed in claim 9, comprising:
placing each of the one or more fuses (202C) equidistant from each other.
11. The method (500) as claimed in claim 10, wherein the one or more fuses (202C) are stacked in parallel such that the stack is symmetrical about a point of current entry.
12. The method (500) as claimed in claim 9, comprising:
preconfiguring a tolerance level for each of the one or more fuses (202C) in a low level compared to a tolerance level of the battery pack (204) and the plurality of cells (204A) with respect to the magnitude of the current flow reaching the third predetermined threshold.
13. The method (500) as claimed in claim 1, comprising:
tripping the one or more fuses (202C) if a microcontroller and a control unit is in a disable state when the magnitude of the current flow reaching the third predetermined threshold.
14. A system (200) of overcurrent protection in a battery pack (204), wherein the system (200) is configured to:
measure a current flow through the battery pack (204);
detect that a magnitude of a current flow through the battery pack (204) is within a predefined range; and
perform one of:
disconnect a switch (202B) if the magnitude of the current flow being in a first predetermined threshold of the predefined range or being in a second predetermined threshold of the predefined range; or
trip one or more fuses (202C) if the magnitude of the current flow reaches a third predetermined threshold of the predefined range.
15. The system (200) as claimed in claim 14, wherein the system (200) is configured to filter noises in a current sensing path configured between the battery pack (204) and an external power source for measuring the current flow.
16. The system (200) as claimed in claim 15, wherein the system (200) is configured to:
detect that the current flow exceeds a constant predefined value using a microcontroller;
detect that the current flow reaches the first predetermined threshold; and
determine that the current flow is being in the first predetermined threshold for a first predefined time period.
17. The system (200) as claimed in claim 16, wherein the system (200) is configured to:
transmit a control signal to the switch (202B) for disconnecting the current flow through the battery pack (204) using the microcontroller.
18. The system (200) as claimed in claim 17, wherein the system (200) is configured to:
detect that the current flow through the battery pack (204) reaches the second predetermined threshold using a control unit;
determine that the current flow being in the second predetermined threshold for a second predefined time period; and
trigger the switch (202B) for disconnecting the current flow through the battery pack (204) in response to the current flow being in the second predetermined threshold for the second predefined time period.
19. The system (200) as claimed in claim 18, wherein the system (200) is configured to:
tune the first predefined time period and the second predefined time period based on a tolerance level of the battery pack (204), the microcontroller, and the control unit with respect to the magnitude of the current flow being in the first predefined threshold and being in the second predefined threshold.
20. The system (200) as claimed in claim 19, wherein the system (200) is configured to:
tune the first predefined time period and the second predefined time period based on a frequency of occurrence of the magnitude of the current flow reaching the first predetermined threshold and the second predetermined threshold.
21. The system (200) as claimed in claim 20, wherein the switch (202B) is positioned between the battery pack (204) and the external power source.
22. The system (200) as claimed in claim 14, wherein each of the one or more fuses (202C) is positioned in parallel between the battery pack (204) and an external power source/load or each of the one or more fuses (202C) are positioned in parallel and configured with each series connection of a plurality of cells (204A) of the battery pack (204).
23. The system (200) as claimed in claim 22, wherein the one or more fuses (202C) are placed equidistant from each other.
24. The system (200) as claimed in claim 23, wherein the one or more fuses (202C) are stacked in parallel such that the stack is symmetrical about a point of current entry.
25. The system (200) as claimed in claim 22, wherein a tolerance level for each of the one or more fuses (202C) is preconfigured with a low level compared to a tolerance level of the battery pack (204) and the plurality of cells (204A) with respect to the magnitude of the current flow reaching the third predetermined threshold.
26. The system (200) as claimed in claim 14, wherein the one or more fuses (202C) are tripped if a microcontroller and a control unit are in a disable state when the magnitude of the current flow reaching the third predetermined threshold.