Description:FIELD
The present disclosure relates to the field of electric vehicles, and more specifically the disclosure relates to a charging system for electric vehicles (EVs) operating in constant voltage (CV) mode and a method thereof. Moreover, the present disclosure discloses the correction of charging voltage demand, after a battery management system (BMS) has entered into the constant voltage (CV) mode.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art. In electric vehicles (EVs) and other applications, charging systems are designed to operate efficiently by continuously monitoring the battery’s voltage. Voltage sensing is crucial for ensuring that the charger delivers the appropriate amount of power, adjusting both current and voltage in real-time to match the battery’s needs. However, when this sensing mechanism fails, it introduces significant challenges to the system's performance and safety.
Charging systems depend heavily on continuous voltage sensing to regulate and manage the charging process. If the voltage sensor malfunctions or provides inaccurate readings, the system loses its ability to properly assess the battery’s state. This can lead to two main issues: charging inefficiency and overcharging risks. In cases where accurate voltage readings are unavailable, many systems default to a safe mode, limiting power output or prematurely ending the charging process. This results in longer charging times or incomplete charging. On the other hand, if the system fails to detect that the battery is fully charged, it may continue charging, which can cause overheating or overcharging, damaging the battery cells and reducing their lifespan.
A related issue is the lack of feedback mechanisms from the Battery Management System (BMS). The BMS is responsible for monitoring critical battery parameters such as temperature, voltage, and current. When the voltage sensing system fails, many charging systems lack sufficient feedback or error correction to adjust accordingly. Without this feedback, the charger may continue operating as if nothing is wrong, further increasing the risk of battery damage. Moreover, a BMS that does not account for voltage sensing failures may fail to trigger essential safety features, leaving the system vulnerable to conditions like overcurrent, overheating, or overvoltage.
Improper voltage sensing poses serious risks. If the system outputs a higher voltage than necessary due to faulty sensing, this can lead to excessive current flow into the battery cells, overwhelming them. This excessive current not only heats the cells but can also lead to battery degradation, thermal runaway, or even fires in severe cases. Over time, repeated instances of overcharging or high current can significantly reduce the battery's lifespan, lower its efficiency, and increase the likelihood of catastrophic failure.
Therefore, there is a need in the art for a charging system for electric vehicles (EVs) operating in constant voltage (CV) mode and method thereof to alleviate the aforementioned disadvantages.
OBJECTS OF THE PRESENT DISCLOSURE
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a charging system for electric vehicles (EVs) operating in constant voltage (CV) mode and method thereof.
Another object of the present disclosure is to overcome the problem of battery charging failures caused by sensor malfunctions in electric vehicle (EV) chargers by providing a charging system for electric vehicles (EVs) operating in constant voltage (CV) mode and method thereof.
Still another object of the present disclosure is to provide a backup method for maintaining a constant voltage even in the event of sensor failure, thereby ensuring full and efficient charging cycles.
Still another object of the present disclosure is to provide real-time error correction by providing a charging system for electric vehicles (EVs) operating in constant voltage (CV) mode and method thereof.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
This summary is provided to introduce concepts related to a charging system for electric vehicles (EVs) operating in constant voltage (CV) mode and a method thereof. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
Various embodiments of the present disclosure relate to a charging system designed for electric vehicles and include a charger that supplies voltage to a battery and a Battery Management System (BMS) that monitors and controls charging. The system operates in CV mode, ensuring stable and accurate charging.
In an embodiment, the charging system includes a charger with an output voltage sensing module and a BMS that continuously monitors the bus and battery voltages. A compensatory mechanism compares the bus voltage and charger output voltage and calculates an error value to correct the voltage demand, ensuring accurate charging even if the charger’s sensor fails.
In an embodiment, the compensatory mechanism includes a calibratable factor that adjusts the corrected voltage demand based on design requirements. Additionally, a voltage offset mechanism ensures a consistent and linear charging profile under sensor failure conditions, enhancing battery longevity.
A hardware control module within the charger limits current flow to protect the battery from overcurrent conditions during charging, especially in cases of sensor malfunction.
The BMS also assesses the battery's state of health (SOH), considering factors such as capacity and cycle life. The BMS uses this information to calculate the voltage demand required to charge the battery.
In an embodiment, the BMS communicates with the charger via a Controller Area Network (CAN) bus protocol, allowing real-time data exchange for accurate voltage adjustments.
In an embodiment, the system operates in real-time to dynamically adjust the voltage demand based on feedback from the BMS, which continuously monitors the battery’s condition.
The present disclosure also envisages a method for managing battery charging in an EV. The method includes steps such as:
sensing, by a charger output voltage sensing module, a charger’s output voltage;
determining, by a processing unit, a voltage demand for charging the battery based on monitored bus and battery voltages;
calculating, by the processing unit, an error value based on a difference between the bus voltage and the charger’s output voltage;
comparing, by a compensatory mechanism, the bus voltage sensed by a battery management system (BMS) with the charger’s output voltage;
adjusting the voltage demand by adding the error value to a BMS voltage demand to obtain a corrected voltage demand;
adjusting, by the charger, its output voltage based on the corrected voltage demand to maintain stable and accurate charging despite potential sensor failures within the charger;
processing, by a control module, incoming voltage data from a monitoring unit of the BMS and adjusting the voltage demand to ensure optimal charging conditions;
executing, by the control module, a feedback mechanism to continuously monitor the charger’s output voltage and adjust charging parameters to prevent overcharging and enhance battery longevity;
continuously monitoring, by a bus voltage sensing module of the BMS, a bus voltage;
monitoring, by a battery pack voltage sensing module of the BMS, a battery voltage of the battery and detecting the state of individual battery cells;
assessing, by a state of health (SOH) monitoring function of the BMS, the overall condition of the battery using metrics comprising capacity, internal resistance, and cycle life; and
facilitating, by a communication interface implemented using a Controller Area Network (CAN) bus protocol, real-time data exchange between the BMS and the charger.
In an embodiment, the method further includes applying a positive voltage offset through a voltage adjustment circuit to maintain charging consistency during sensor malfunctions and limiting current flow to protect the battery from overcurrent conditions.
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 numerals represent components.
It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawing and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWING
A charging system for electric vehicles (EVs) operating in constant voltage (CV) mode and a method thereof, of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a schematic block diagram of a charging system for electric vehicles (EVs) operating in constant voltage (CV) mode in accordance with an embodiment of the present disclosure;
Figure 2 illustrates an enlarged block diagram of a monitoring unit of the charging system for electric vehicles (EVs) operating in constant voltage (CV) mode in accordance with an embodiment of the present disclosure;
Figure 3 illustrates a block diagram of an electric vehicle and charger interface with voltage sensors of the charging system for electric vehicles (EVs) operating in constant voltage (CV) mode in accordance with an embodiment of the present disclosure;
Figure 4 illustrates a flow diagram of a method for managing battery charging in an electric vehicle charging system operating in constant voltage (CV) mode in accordance with an embodiment of the present disclosure; and
Figures 5a-5d illustrate an exemplary method for managing battery charging in an electric vehicle charging system operating in constant voltage (CV) mode in accordance with an embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS
1000 Electric Vehicle (EV)
100 Charging System
101 Charger
101a Charger Output Voltage Sensing Module
101b Processing Unit
101c Compensatory Mechanism
101d Control Module
1011d Feedback Mechanisms
101e Voltage Offset Mechanism
101f Hardware Control Module
102 Battery
103 Battery Management System (BMS)
103a Monitoring Unit
1031a Bus Voltage Sensing Module
1032a Battery Pack Voltage Sensing Module
1033a State Of Health (SOH) Monitoring Function
103b Communication Interface
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details, are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being "mounted on," “engaged to,” "connected to," or "coupled to" another element, it may be directly on, engaged, connected, or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer, or section from another component, region, layer, or section. Terms such as first, second, third, etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Terms such as “inner,” “outer,” "beneath," "below," "lower," "above," "upper," and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
The present disclosure relates to a vehicle propulsion system, and more specifically, relates to a charging system for electric vehicles (EVs) operating in constant voltage (CV) mode and a method thereof.
In electric vehicles (EVs) and other applications, charging systems are designed to operate efficiently by continuously monitoring the battery’s voltage. Voltage sensing is crucial for ensuring that the charger delivers the appropriate amount of power, adjusting both current and voltage in real-time to match the battery’s needs. However, when this sensing mechanism fails, it introduces significant challenges to the system's performance and safety.
Charging systems depend heavily on continuous voltage sensing to regulate and manage the charging process. If the voltage sensor malfunctions or provides inaccurate readings, the system loses its ability to properly assess the battery’s state. This can lead to two main issues: charging inefficiency and overcharging risks. In cases where accurate voltage readings are unavailable, many systems default to a safe mode, limiting power output or prematurely ending the charging process. This results in longer charging times or incomplete charging. On the other hand, if the system fails to detect that the battery is fully charged, it may continue charging, which can cause overheating or overcharging, damaging the battery cells and reducing their lifespan.
A related issue is the lack of feedback mechanisms from the Battery Management System (BMS). The BMS is responsible for monitoring critical battery parameters such as temperature, voltage, and current. When the voltage sensing system fails, many charging systems lack sufficient feedback or error correction to adjust accordingly. Without this feedback, the charger may continue operating as if nothing is wrong, further increasing the risk of battery damage. Moreover, a BMS that does not account for voltage sensing failures may fail to trigger essential safety features, leaving the system vulnerable to conditions like overcurrent, overheating, or overvoltage.
Improper voltage sensing poses serious risks. If the system outputs a higher voltage than necessary due to faulty sensing, this can lead to excessive current flow into the battery cells, overwhelming them. This excessive current not only heats the cells but can also lead to battery degradation, thermal runaway, or even fires in severe cases. Over time, repeated instances of overcharging or high current can significantly reduce the battery's lifespan, lower its efficiency, and increase the likelihood of catastrophic failure.
Therefore, there is a need in the art for a charging system 100 for electric vehicles (EVs) 1000 operating in constant voltage (CV) mode and method 200 thereof. The charging system 100 for electric vehicles (EVs) 1000 operating in constant voltage (CV) mode will now be described with reference to Figures 1-3, and method 200 for managing battery charging in an electric vehicle 1000 charging system 100 operating in constant voltage (CV) mode will be described with reference to Figures 5a-5d.
According to the present disclosure, in battery charging, constant current (CC) mode and constant voltage (CV) mode are two distinct phases that help to ensure safe and efficient charging, especially for rechargeable batteries.
In CC mode, the charger supplies a fixed current to the battery, which is kept constant by controlling the charging voltage. The voltage gradually rises as the battery charges, but the current remains steady. This mode helps to quickly bring the battery up to a high charge level without exceeding safe voltage limits. It is especially useful for the initial phase of charging, where the battery is at a lower state of charge (SOC) and can safely handle higher currents.
Once the battery voltage reaches a preset maximum value (often called the “float voltage”), the charger switches to CV mode. In this mode, the voltage is kept constant at this maximum value, and the current gradually decreases as the battery continues to charge. CV mode safely “tops off” the battery by reducing the current as it reaches full capacity. This prevents overcharging and minimizes stress on the battery.
The transition from CC to CV mode occurs when any of the cell voltage reaches the maximum allowable charging voltage in a battery pack (e.g., 4.2V for a single lithium-ion cell in a battery pack). At this point, the charger stops trying to increase the voltage further to prevent potential overcharging, the charger enters CV mode, holding the voltage constant while the battery absorbs the remaining charge, and the current starts to taper off naturally as the battery approaches full charge.
Figure 1 illustrates a schematic diagram of a charging system 100 for electric vehicles (EVs) 1000 operating in constant voltage (CV) mode in accordance with an embodiment of the present disclosure. As shown in Figure 1, the vehicle 1000, the charging system 100, a charger 101, a charger output voltage sensing module 101a, a processing unit 101b, a compensatory mechanism 101c, a control module 101d, a voltage offset mechanism 101e, a hardware control module 101f, a battery 102, a battery management system (BMS) 103, a monitoring unit 103a, and a communication interface 103b are illustrated.
In continuation with reference to Figure 1 and as illustrated in Figure 2 and Figure 3, the charging system 100 for electric vehicles (EVs) 1000 operating in constant voltage (CV) mode comprises the charger 101 which is configured to supply voltage to the battery 102. The charger 101 includes the charger output voltage sensing module 101a that is configured to sense the charger’s output voltage. Further, the charger 101 includes a processing unit 101b that is configured to determine a voltage demand for charging the battery 102 based on the monitored bus and battery voltages. The processing unit 101b is further configured to calculate an error value based on the difference between the bus voltage and the charger’s output voltage, allowing for adjustments to the charging demand.
In continuation with reference to Figure 1, the compensatory mechanism 101c is configured to compare the bus voltage sensed by the BMS 103 with the charger’s output voltage. The compensatory mechanism 101c adjusts the voltage demand by adding the error value to the BMS voltage demand to obtain a corrected voltage demand. The charger 101 adjusts its output voltage based on the corrected voltage demand, thereby maintaining stable and accurate charging despite potential sensor failures within the charger 101. The compensatory mechanism 101c operates continuously in real-time to dynamically adjust the voltage demand based on a feedback mechanism in the charger 101 to ensure full battery charging even in the event of charger sensor malfunctions.
In an embodiment, the compensatory mechanism 101c further comprises a calibratable factor X. The corrected voltage demand is calculated as:
Corrected Voltage Demand=(BMS Voltage Demand-Bus Voltage)+Charger Output Voltage+ X
wherein, X is adjustable between 0 to 2V based on design requirements.
The control module 101d is configured to process incoming voltage data from the monitoring unit 103a and adjust the voltage demand accordingly. The control module 101d is further configured to communicate the corrected voltage demand to the BMS 103 via the communication interface 103b, ensuring optimal charging conditions. In an embodiment, the control module 101d is further configured to execute feedback mechanisms 1011d that allow for continuous monitoring of the charger’s 101 output voltage and adjustment of charging parameters to prevent overcharging and enhance battery 102 longevity.
In continuation with reference to Figure 1, the charger 101 further comprises a voltage offset mechanism 101e which is configured to apply a slight positive voltage offset to the corrected voltage demand to maintain a consistent and linear charging profile under sensor failure conditions. The hardware control module 101f is configured to limit the current flow into the battery based on the corrected voltage demand to protect the battery cells from overcurrent conditions during sensor failures.
Now as shown in Figure 2 and as shown in Figure 3, the battery management system 103 (BMS) comprises the monitoring unit 103a includes a bus voltage sensing module 1031a which is configured to continuously monitor the bus voltage. A battery pack voltage sensing module 1032a is configured to monitor the battery voltage of battery 102 and detect the state of individual battery cells. A state of health (SOH) monitoring function 1033a is configured to assess the overall condition of the battery, comprising metrics including capacity, internal resistance, and cycle life. In an embodiment, the BMS 103 continuously monitors the state of health (SOH) 1033a of battery 102 and communicates with the charger 101 to adjust the charging profile to optimize battery 102 life.
The communication interface 103b is implemented by a Controller Area Network (CAN) bus protocol and is configured to facilitate real-time data exchange between the BMS 103 and the charger 101. The communication interface 103b is capable of transmitting battery parameters such as bus voltage, BMS demand, CV mode, voltage readings, error values, and adjusted voltage demands calculated in charger 101 from the BMS 103 to charger 101.
Figure 4 illustrates a flow diagram of method 200 for managing battery charging in an electric vehicle 1000 charging system 100 operating in constant voltage (CV) mode in accordance with an embodiment of the present disclosure. Method 200 for managing battery charging in an electric vehicle 1000 charging system 100 operating in constant voltage (CV) mode is illustrated in Figures 5a-5d. Method 200 comprises the following method steps for managing battery charging in an electric vehicle 1000 using the charging system 100 operating in constant voltage (CV) as illustrated in Figures 1-3:
sensing 202, by a charger output voltage sensing module 101a of a charger 101, a charger’s output voltage;
determining 204, by a processing unit 101b of the charger 101, a voltage demand for charging the battery 102 based on monitored bus and battery voltages;
calculating 206, by the processing unit 101b, an error value based on a difference between a bus voltage and the charger’s output voltage;
comparing 208, by a compensatory mechanism 101c, the bus voltage sensed by a bus voltage sensing module 1031a of a battery management system BMS 103 with the charger’s output voltage;
adjusting 210, by the compensatory mechanism 101c, the voltage demand by adding the error value to a BMS voltage demand to obtain a corrected voltage demand;
adjusting 212, by the charger 101, its output voltage based on the corrected voltage demand to maintain stable and accurate charging despite potential sensor failures within the charger 101;
processing 214, by a control module 101d of the charger 101, incoming voltage data from a monitoring unit 103a of the BMS 103 and adjusting the voltage demand to ensure optimal charging conditions;
executing 216, by the control module 101d, a feedback mechanism 1011d to continuously monitor the charger’s 101 output voltage and adjust charging parameters to prevent overcharging and enhance battery 102 longevity;
continuously monitoring 218, by the bus voltage sensing module 1031a of the monitoring unit 103a, a bus voltage;
monitoring 220, by a battery pack voltage sensing module 1032a of the monitoring unit 103a, a battery voltage of the battery 102 and detecting the state of individual battery cells;
assessing 222, by a state of health SOH monitoring function 1033a of the monitoring unit 103a, an overall condition of the battery 102 using metrics comprising capacity, internal resistance, and cycle life; and
facilitating 224, by a communication interface 103b implemented using a Controller Area Network CAN bus protocol, real-time data exchange between the BMS 103 and the charger 101.
In an embodiment, method 200 further comprises the method step of applying 226 a positive voltage offset through a voltage adjustment circuit within the charger 101 to ensure consistent charging despite sensor malfunctions.
In an embodiment, method 200 further comprises the method step of limiting 228, by a hardware control module 101f of the charger 101, the current flow into the battery 102 based on the corrected voltage demand to protect the battery cells from overcurrent conditions during sensor failures.
In an embodiment, the system 100 can be used in electric vehicle 1000 charging systems 100 where reliable, accurate voltage sensing is crucial for maximizing battery life and performance.
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENT
The present disclosure described hereinabove has several technical advantages including, but not limited to a charging system for electric vehicles (EVs) operating in constant voltage (CV) mode and method thereof, that;
overcomes the problem of battery charging failures caused by sensor malfunctions in electric vehicle (EV) chargers;
provides a backup method for maintaining a constant voltage even in the event of sensor failure;
provides dynamic error compensation based on real-time data from BMS;
provides optional voltage offset to ensure slightly higher voltage demand for maintaining a consistent charging curve;
reduces the risk of undercharging, resulting in better performance and range in EVs; and
ensures that the charging process remains stable and efficient, even when the charger’s voltage sensors malfunction due to temperature-related failures.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Any discussion of devices, articles, or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:WE CLAIM:
A charging system (100) for electric vehicles (EVs) (1000) operating in constant voltage (CV) mode, comprising:
a charger (101) configured to supply voltage to a battery (102), said charger (101) comprises;
a charger output voltage sensing module (101a) configured to sense charger’s output voltage;
a processing unit (101b) is configured to determine a voltage demand for charging the battery (102) based on the monitored bus and battery voltages, said processing unit (101b) is further configured to calculate an error value based on the difference between the bus voltage and the charger’s output voltage, allowing for adjustments to the charging demand;
a compensatory mechanism (101c) configured to:
compare the bus voltage sensed by a BMS (103) with the charger’s output voltage;
adjust the voltage demand by adding the error value to the BMS voltage demand to obtain a corrected voltage demand; anda control module (101d) configured to process incoming voltage data from a monitoring unit (103a) and adjust the voltage demand accordingly, , ensuring optimal charging conditions; and said control module (101d) is further configured to execute feedback mechanisms (1011d) that allow for continuous monitoring of the charger’s (101) output voltage and adjustment of charging parameters to prevent overcharging and enhance battery (102) longevity;
said battery management system (103) (BMS) comprising:
the monitoring unit (103a) including:
a bus voltage sensing module (1031a) configured to continuously monitor a bus voltage;
a battery pack voltage sensing module (1032a) configured to monitor a battery voltage of the battery and detect the state of individual battery cells; and
a state of health (SOH) monitoring function (1033a) configured to assess the overall condition of the battery, comprising metrics including capacity, internal resistance, and cycle life; and
the communication interface (103b) implemented by a Controller Area Network (CAN) bus protocol and configured to facilitate real-time data exchange between the BMS (103) and the charger (101).

The system (100) as claimed in claim 1, wherein the compensatory mechanism (101c) further comprises a calibratable factor X, wherein the corrected voltage demand is calculated as:
Corrected Voltage Demand=(BMS Voltage Demand-Bus Voltage)+Charger Output Voltage+ X
Wherein, X is adjustable between 0 to 2V based on design requirements.
The system (100) as claimed in claim 1, wherein the charger (101) further comprises a voltage offset mechanism (101e) configured to apply a slight positive voltage offset to the corrected voltage demand to maintain a consistent and linear charging profile under sensor failure conditions.
The system (100) as claimed in claim 1, wherein the compensatory mechanism (101c) operates continuously in real-time to dynamically adjust the voltage demand based on feedback in the charger (101) to ensure full battery charging even in the event of charger sensor malfunctions.
The system (100) as claimed in claim 1, wherein the charger (101) further comprises a hardware control module (101f) configured to limit the current flow into the battery based on the corrected voltage demand to protect the battery cells from overcurrent conditions during sensor failures.
The system (100) as claimed in claim 1, wherein the BMS (103) continuously monitors the state of health (SOH) (1033a) of the battery (102) and communicates with the charger (101) to adjust the charging profile to optimize battery (102) life.
A method (200) for charging an electric vehicle (EV) battery (102) in constant voltage (CV) mode using a charging system (100), the method comprising:
sensing (202), by a charger output voltage sensing module (101a) of a charger (101), a charger’s output voltage;
determining (204), by a processing unit (101b) of the charger (101), a voltage demand for charging the battery (102) based on monitored bus and battery voltages;
calculating (206), by the processing unit (101b), an error value based on a difference between a bus voltage and the charger’s output voltage;
comparing (208), by a compensatory mechanism (101c), the bus voltage sensed by a bus voltage sensing module (1031a) of a battery management system (BMS) (103) with the charger’s output voltage;
adjusting (210), by the compensatory mechanism (101c), the voltage demand by adding the error value to a BMS voltage demand to obtain a corrected voltage demand;
adjusting (212), by the charger (101), its output voltage based on the corrected voltage demand to maintain stable and accurate charging despite potential sensor failures within the charger (101);
processing (214), by a control module (101d) of the charger (101), incoming voltage data from a monitoring unit (103a) of the BMS (103) and adjusting the voltage demand to ensure optimal charging conditions;
executing (216), by the control module (101d), a feedback mechanism (1011d) to continuously monitor the charger’s (101) output voltage and adjust charging parameters to prevent overcharging and enhance battery (102) longevity;
continuously monitoring (218), by the bus voltage sensing module (1031a) of the monitoring unit (103a), a bus voltage;
monitoring (220), by a battery pack voltage sensing module (1032a) of the monitoring unit (103a), a battery voltage of the battery (102) and detecting the state of individual battery cells;
assessing (222), by a state of health (SOH) monitoring function (1033a) of the monitoring unit (103a), an overall condition of the battery (102) using metrics comprising capacity, internal resistance, and cycle life; and
facilitating (224), by a communication interface (103b) implemented using a Controller Area Network (CAN) bus protocol, real-time data exchange between the BMS (103) and the charger (101).

The method (200) as claimed in claim 7, further comprises the step of applying (226) a positive voltage offset through a voltage adjustment circuit within the charger (101) to ensure consistent charging despite sensor malfunctions.
The method (200) as claimed in claim 7, further comprises the step of limiting (228), by a hardware control module (101f) of the charger (101), the current flow into the battery (102) based on the corrected voltage demand to protect the battery cells from overcurrent conditions during sensor failures.

Dated this 06th Day of January 2025

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT