Description:FIELD OF THE INVENTION
[0001] The present subject matter is related, in general to a battery pack, and more particularly, but not exclusively to a method for regulating currents in the battery pack.
BACKGROUND OF THE INVENTION
[0002] In the development of battery technology for industrial applications there exist critical safety concerns with regard to propensity of fire hazards through thermal runaway as well as through short circuiting. In view of the popularity battery packs hold in our day-to-day life there is a dire need for development of appropriate infrastructure which monitor the real time functioning of the battery packs as well as activate appropriate safety mechanisms to cope with the detected anomaly.
[0003] Battery packs, in essence, are a source of electrical energy which is supplied to an electrical load for its functioning. The battery pack consists of a plurality of battery cells which are electrically connected in parallel, or series configuration based on the required power output and current output to be supplied by the battery pack. Battery packs are used in a broad spectrum of industrial applications and equipment and are also a critical component in electric and hybrid vehicle development.
[0004] While it is known in the art, to provide the battery pack with a Battery Management System (hereinafter referred to as BMS) which monitors individual parameters of the cells comprising the battery pack. The parameters monitored by the BMS include State of Charge (hereinafter referred to as SoC) and a State of Health (hereinafter referred to as SoH) of the battery pack. However, the functionality of the BMS in the battery pack, as known in the art, is limited to mere monitoring and detection of miscellaneous electrical anomalies in the battery pack, while the BMS fails to provide an active coping mechanism to diagnose the detected electrical anomaly.
[0005] Additionally, there is no existing safety infrastructure or mechanism deployed in the battery pack which protects the BMS against miscellaneous electrical anomalies occurring in the battery pack. The absence of a safety infrastructure to protect the BMS would result in tarnishing the functionality of the electronic or electrical component as well in which the battery pack with the BMS is disposed.
[0006] Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings.
SUMMARY
[0007] 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 drawings and the following detailed description.
[0008] According to embodiments illustrated herein, a battery pack comprising a plurality of cells, a battery management system (hereinafter referred to as BMS) and a current regulating circuit. The current regulating circuit comprises a plurality of high resistance paths, a plurality of low resistance paths, a plurality of switching units and a control assembly. The plurality of high resistance paths and the plurality of low resistance paths are electrically connected to the plurality of cells. The control assembly comprises one or more control units with a first control unit being a master control unit and a second control unit being a slave control unit. The slave control unit is functionally connected to the plurality of low resistance paths, the plurality of high resistance paths and the plurality of switching units. The master control unit is functionally connected to the slave control unit.
[0009] According to embodiments illustrated herein, a method for regulating currents in a battery pack comprises steps: receiving, by a master control unit, a BMS temperature data from a plurality of temperature sensors; comparing, by the master control unit, the BMS temperature data with a pre-defined threshold BMS temperature; and configuring, by the master control unit, a slave control unit to open a plurality of switching units when the BMS temperature data is beyond the pre-defined threshold BMS temperature and close the plurality of switching units when the BMS temperature data is less than the pre-defined threshold BMS temperature. The plurality of temperature sensors being disposed in a BMS and the plurality of switching units are disposed in each of an electrical path of a plurality of cells of the battery pack.
[00010] According to embodiments illustrated herein, the master control unit is further configured to trigger a service alert when the sensed BMS temperature data is continuously beyond the pre-defined threshold BMS temperature over a pre-defined threshold time period.
[00011] According to embodiments illustrated herein, the master control unit configures the slave control unit to close the plurality of switching means when the sensed BMS temperature data is restored below the pre-defined threshold BMS temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
[00012] The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention.
[00013] Figure 1 exemplarily illustrates a block diagram of a battery pack, in accordance with some embodiments of the present disclosure.
[00014] Figure 2 illustrates a block diagram of a current regulating circuit, in accordance with some embodiments of the present disclosure.
[00015] Figure 3 illustrates a circuit diagram of the current regulating circuit, in accordance with some embodiments of the present disclosure.
[00016] Figure 4 depicts flowchart illustrating a method performed by a master control unit, in accordance with some embodiments of the present disclosure.
[00017] Figure 5 depicts a flowchart for implementation of an exemplary embodiment of the master control unit, in accordance with some embodiments of the present disclosure.
DETAILED DESCRIPTION
[00018] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.
[00019] References to “one embodiment,” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment.
[00020] The present invention now will be described more fully hereinafter with different embodiments. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather those embodiments are provided so that this disclosure will be thorough and complete, and fully convey the scope of the invention to those skilled in the art.
[0001] The present invention is illustrated with a battery pack. However, a person skilled in the art would appreciate that the present invention is not limited to a battery pack and certain features, aspects and advantages of embodiments of the present invention can be extended to other forms of energy storage devices used with various types of vehicles, electric vehicle, hybrid vehicles and other forms of electrical and electronic equipment requiring an energy storage device. In an embodiment, the battery pack is configured to supply electrical energy to an external electrical load. The electrical load refers to, but is not limited to, electrical vehicles, hybrid vehicles and other electrical and electronic equipment requiring electrical energy. Additionally, the term “vehicle” used in the present disclosure shall not be narrowly construed to relate to two, three or four-wheeler vehicles but shall be extended to all forms of mobility and locomotion capable of drawing or utilizing electrical energy from a battery pack or an energy storage device for its operation.
[00021] The object of the present subject matter is to protect the electronic components present in the BMS against any unintentional currents flowing from the cells in the battery pack along any unintentional current paths. The unintentional currents flowing in the battery pact are manifested in the form of local temperature rises in the battery pack.
[00022] To this end, a plurality of temperature sensors are disposed in pre-determined local hot spots of the BMS and the BMS temperature data sensed by the plurality of temperature sensors are transmitted to a slave control unit and a master control unit of the control assembly. The master control unit is configured to compare the received BMS temperature data against a pre-defined threshold BMS temperature. In the event of the BMS temperature data being beyond the pre-defined threshold BMS temperature, the master control unit configures the slave control unit to open a plurality of switching units disposed in each of an electrical path of each of the plurality of cells, to put to halt the circulation of unintentional currents in the battery pack. In the event of the BMS temperature data being less than the pre-defined threshold BMS temperature, the master control unit configures the slave control unit to close a plurality of switching units, to resume normal functioning of the battery pack.
[00023] The object of the present subject matter is to provide real-time monitoring of plurality of cell parameters of the battery pack and diagnose the detected electrical anomalies to resume normal operation of the battery pack.
[00024] To this end, the battery pack in accordance with the disclosed configuration is equipped with a current regulating circuit comprising a plurality of high resistance paths and a plurality of low resistance paths. The plurality of high resistance paths and the plurality of low resistance paths are electrically connected to a plurality of cells of the battery pack. The plurality of high resistance paths are configured to monitor cell voltages of each cell of the plurality of cells of the battery pack. The plurality of low resistance paths are configured to balance any cell imbalances detected in the plurality of cells of the battery pack where the resistors disposed in the plurality of low resistance path continuously discharge an anomalous cell detected in the battery pack.
[00025] In conventional battery packs, the function of the BMS is merely limited to monitoring and detection of miscellaneous electrical anomalies in the battery pack. However, there is no fail-safe mechanism or coping mechanism employed to diagnose the miscellaneous electrical anomalies in the battery pack.
[00026] The present subject matter addresses this exact drawback of the conventional battery packs by equipping the battery pack with a current regulating circuit comprising a plurality of high resistance paths for monitoring of cell voltages of the plurality of cells, a plurality of low resistance paths for balancing detected cell imbalances in the plurality of cells, a plurality of switching units configured by the control assembly to open and close based on the received BMS temperature data.
[00027] It is another object of the present subject matter to provide a fail-safe mechanism to protect the battery pack against electrical anomalies such as thermal runaway, short circuiting and miscellaneous local temperature rises.
[00028] The present subject matter in accordance with the disclosed configuration configures the master control unit to configure the slave control unit based on the difference in BMS temperature data received from a plurality of temperature sensors and the pre-defined threshold BMS temperature. Since, electrical anomalies in the battery pack such as short circuit and thermal runaway are manifested in the form of local temperature rises, the control assembly continuously monitors the received BMS temperature data and operate the switching units based on the received BMS temperature data.
[00029] It is another object of the present subject matter to restore functionality of the battery pack and consequently of the electrical load once the electrical anomaly detected has been alleviated.
[00030] To this end, upon the opening of the plurality of switches by the slave control unit upon the command of the master control unit, the plurality of high resistance paths still operate in closed circuit and continue to monitor the cell voltages of each cell of the battery pack and the plurality of temperature sensors continue to sense the BMS temperature data and provide the same to the master control unit. Normal operation of the battery pack is resumed once the BMS temperature settles within permissible limits by closing of the plurality of switches by the control assembly.
[00031] The object of the present subject matter is to alleviate potential short circuiting during assembly of the battery pack when electrical connections extending from each cell of the plurality of cells of the battery pack are being electrically connected to the BMS.
[00032] In accordance with the disclosed configuration, the present subject matter employs a junction board configured to receive an electrical connection extending from each of the plurality of cells and provide the received electrical connections to the BMS using a single connector.
[00033] In conventional battery packs, during assembly, each electrical connection represents a plurality of cell parameters including the cell voltages of each cell. When the electrical connections from the plurality of cells are being connected to the BMS directly, due to the electrical connection being connected one after another the existent cell voltage in the electrical connection leads to the creation of a virtual ground yielding to the flow of unintentional currents in the BMS and potential short circuiting in the battery pack.
[00034] The present subject matter addresses this exact drawback of conventional battery packs by providing a junction board, where the junction board receives the electrical connections with the plurality of cell parameters extending from the plurality of cells and transmits the received plurality of cell parameters to the BMS using a single connector, thus ensuring that all the electrical connections are established at the same instant of time, eliminating the potential formation of virtual grounds.
[00035] It is another object of the present subject matter to instantaneously trigger service alert to appropriate authorities in instances where the detected electrical anomaly persists over a pre-defined threshold time period.
[00036] In accordance with the disclosed configuration, the plurality of temperature sensors are configured to continuously provide the sensed BMS temperature data to the master control unit. In the event of the sensed BMS temperature data is continuously beyond the pre-defined threshold BMS temperature beyond a pre-defined threshold time period, the master control unit is configured to trigger a service alert to alert concerned authorities.
[00037] The existing mechanisms known in the art addressing heating concerns in electrical equipment are again limited in protecting the battery cells of the battery pack and no protection of the BMS against miscellaneous electrical and fire hazards have been accorded. Thus, there is a requirement of a safety infrastructure which not only protects the battery cells of the battery pack but also the BMS against miscellaneous electrical and fire hazards.
[00038] In accordance with the present configuration, the plurality of temperature sensors are disposed in pre-determined local hot spots of the BMS and are configured to detect BMS temperature data. The BMS temperature data is then supplied to the master control unit and based on the received BMS temperature data the plurality of switching units are operated to ensure safe operation of the battery pack. The disposition of a plurality of temperature sensors in the BMS allow effective monitoring of BMS parameters for safe operation.
[00039] The embodiments of the present invention will now be described in detail with reference to a battery pack along with the accompanying drawings. However, the present invention is not limited to the present embodiments. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.
[00040] Figure 1 exemplarily illustrates a block diagram of a battery pack, in accordance with some embodiments of the present disclosure.
[00041] With reference to Figure 1, 100 denotes a battery pack, 102 denotes a plurality of cells, 104 denotes a battery management system (hereinafter referred to as BMS), 106 denotes a current regulating circuit and 108 denotes a junction board.
[00042] In an aspect, the battery pack (100) encompasses other forms of energy storage devices such as the battery packs used in electric vehicle, hybrid vehicles and the like and is hereinafter neither limited by application nor by semantics.
[00043] In an aspect, the battery pack (100) comprises of a plurality of cells (102) where the plurality of cells (102) is electrically connected to each other. The plurality of cells (102) is electrically connected to the BMS (104) through the junction board (108). The current regulating circuit (106) is electrically connected to the plurality of cells (102). In an embodiment, the current regulating circuit (106) is disposed in one of the junction board (108) and the BMS (104).
[00044] The term battery pack (100) used in the present disclosure shall be construed to include any electrical equipment configured to store electrical energy and may include a plurality of battery cells, a plurality of battery modules or other forms of electrical energy storage equipment. The battery pack (100) is an energy storage device or an energy storage pack which is configured to store electrical energy and supply the stored electrical energy to an external electrical load as and when required.
[00045] In an aspect, the battery pack (100) may be rechargeable or non-rechargeable dependent on the application for which the battery pack (100) is used. The battery pack (100) has a charged and a discharged state.
[00046] In an embodiment, the battery pack (100) consists of a plurality of battery modules connected in series, with each battery module having a plurality of cells (102) connected in parallel. In an aspect, the plurality of cells (102) are disposed in one or more holders which hold the cells in the required position to maintain cell arrangement and cell spacing. The battery pack (100) includes one or more interconnectors which establish an electrical connection between the plurality of cells (100) disposed in a battery module. The plurality of cells (102) is welded to the interconnector to form the battery module of the battery pack.
[00047] In an aspect, the plurality of cells (102) may be stacked in a battery module wherein the plurality of cells (102) inside the battery module being connected in parallel. A plurality of battery modules may then be connected in series to form the plurality of cells (102) as illustrated and disclosed in the present disclosure.
[00048] The disposition of the plurality of cells (102) is such that a pre-defined gap exists between the adjacent cells of the plurality of cells (102). The configuration of the plurality of cells (102) with a pre-defined gap ensures no shorting occurring between the plurality of cells (102). In an embodiment, the pre-defined gap between adjacent cells of the plurality of cells (102) is in a range of 10 mm to 15 mm.
[00049] In another embodiment, the battery pack (100) comprises of the plurality of cells (102) where the plurality of cells (102) are electrically connected in series with each other. In a series connection, the positive of one cell is connected to a negative of the adjacent cell, such that the number of electrical connections extending from the plurality of cells (102) is equal to the number of the plurality of cells (102).Thus, the number of electrical connections extending from the plurality of cells (102) and connecting to the junction board (108) are equal to the number of cells in the plurality of cells (102).
[00050] The BMS (104) plays a vital role in monitoring the health of the battery pack (100). The BMS (104) is configured to monitor the cell voltage, charging current, temperature, state of charge, and the like of the plurality of cells (102), or modules of the battery pack (100) for ensuring effective working and long life of the battery pack (100).
[00051] The BMS (104) comprises of suitable logic, circuitry interfaces, and/or code that is configured to receive a plurality of cell parameters through electrical connections extending from the plurality of cells (102). The BMS (104) is configured to receive the plurality of cell parameters from the plurality of cells (102). The BMS (104) is configured to monitor the state of charge and the state of health of the plurality of cells (102) and thus the connection between the BMS (104) and the plurality of cells (102) must be secure for efficient working of the battery pack (100). In an aspect, the BMS (104) is configured to monitor a plurality of cell parameters of the plurality of cells (102).
[00052] In an aspect, the BMS (104) may be configured to include a memory which may be implemented based on a Random Access Memory (RAM), a Read-Only Memory (ROM), a Hard Disk Drive (HDD), a storage server, and/or a Secure Digital (SD) card for storing battery pack related parameters.
[00053] In an embodiment, a set of temperature sensors are disposed in the plurality of cells (102) based on localized hot-spots in the plurality of cells (102).
[00054] In an aspect, the electrical connections extending from the plurality of cells (102) are electrically connected to the junction board (108), wherein the junction board (108) in turn is electrically connected to the BMS (104). The junction board (108) is configured to receive the electrical connections extending from each cell of the plurality of cells (102), temperature input through connections extending from the set of temperature sensors and a ground wire. The junction board (108) further transmits the received electrical connections, temperature inputs and the ground wire to the BMS (104) through a single connector.
[00055] In an embodiment, the junction board (108) is a printed circuit board or a metal substrate.
[00056] In operation, electrical connections extending from each cell of the plurality of cells (102) of the battery pack (100) connect to the BMS (106) through the junction board (108). The electrical connections extending from each cell comprise of a plurality of cell parameters. The plurality of cell parameters include at least one of a state of charge, a state of health, cell current, cell voltage, cell temperature of each of the plurality of cells. The cell voltage levels and the temperature output of the plurality of cells (102) are provided to the junction board (108), the BMS (104) draws this information from the junction board (108).
[00057] The electrical connections extending from each cell of the plurality of cells (102), in conventional battery packs, are directly connected to the BMS (104). However, the electrical connections when connected to the BMS (104) result in the gap between the electrical connections on the BMS (104) being too close to each other. In an embodiment, the gap between the electrical connections on the BMS (104) is less than 1.5 mm. Due to the reduced gap between the electrical connections on the BMS (104) the chances of shorting occurring at the BMS (104) end increases, subsequently the BMS (104) is prone to circulation of unintentional currents.
[00058] In an aspect of the present invention, in the junction board (108), there is a reduced gap between the electrical connections as those existing in the BMS (104), however the absence of any electronic components performing logic or control functions being disposed in the junction board (108) makes the junction board (108) least susceptible to unintentional currents, and hence its functionality is not jeopardized by the formation of virtual grounds.
[00059] Conventionally, the electrical connections from the plurality of cells (102) with a wire extending from each cell were physically mounted on the BMS (104) one after another. During such mounting, each electrical connection having a charge due to cell voltage is mounted one after another while the ground wire is left floating, this often leads to flowing of unintentional currents in the BMS (104) through unintentional paths because of formation of virtual grounds. This phenomenon results in damage of the electronic components present in the BMS (104).
[00060] The junction board (108) acts as a transmission channel where the received plurality of cell parameters through the electrical connections from the plurality of cells (102) is merely transmitted to the BMS (104) through a single connector. In an aspect, the plurality of battery cells (102) provides a plurality of cell voltages to the junction board (108). The junction board (108) further transmits the received plurality of cell voltages to the BMS (104).
[00061] During assembly of the battery pack (100), the single connector extending from the junction board (108) ensures that all the cell voltages of the electrical connections, the temperature input and the ground wire are connected to the BMS (104) in a single instant of time to avoid the formation of virtual grounds.
[00062] In an embodiment, the present disclosure provides a junction board (108) being placed between the plurality of battery cells (102) and the BMS (104).
[00063] In an aspect, this junction board (108) forms a safety critical function in protecting the BMS (104) against unintentional currents. The junction board (108) is provided with tracks for current flow wherein the cell voltages from the battery pack are supplied at one end of the track while the output to the BMS (104) is at the other end of the track.
[00064] Figure 2 illustrates a block diagram of a current regulating circuit, in accordance with some embodiments of the present disclosure.
[00065] With reference to Figure 2, 202 denotes a plurality of high resistance paths, 204 denotes a plurality of low resistance paths, 206 denotes a plurality of switching units, 208 denotes a control assembly, 210 denotes a slave control unit and 212 denotes a master control unit.
[00066] In an aspect, the current regulating circuit (106) comprises a plurality of high resistance paths (202), a plurality of low resistance paths (204), a plurality of switching units (206) and a control assembly (208). In an aspect, the current regulating circuit (106) is disposed in one of the junction board (108) or the BMS (104).
[00067] In operation, the single connector extending from the junction board (108) comprises of a block of pins, where each pin carries the respective cell voltage of the plurality of cells (102). The output of the junction board (108) comprising of electrical connections extending from the plurality of cells (102) is mandated to flow through the plurality of high resistance paths (202) and the plurality of low resistance paths (204) of the current regulating circuit (106). Thus, the plurality of high resistance paths (202) and the plurality of low resistance paths (204) are electrically connected to the plurality of cells (102).
[00068] In an aspect, each high resistance path (202) of the plurality of high resistance paths (202) is disposed with at least one high resistance resistor. In an embodiment, each cell of the plurality of cells (102) electrically connect to a designated high resistance path (202). In another embodiment, owing to the high resistance resistors deployed in each high resistance path (202), at least two adjacent cells of the plurality of cells (102) are electrically connected to a single designated high resistance path (202).
[00069] The deployment of a high resistance resistor in each high resistance path (202) of the current regulating circuit (106) impedes the flow of current through the high resistance path (202). Thus, each high resistance path (202) functions as a monitoring path which monitors the current and cell voltages of the connected cell of the plurality of cells (102).
[00070] In an aspect, each low resistance path (204) of the plurality of low resistance paths (204) is disposed with at least two low resistance resistors where the at least two low resistance resistors are connected in parallel to each other in each of the low resistance paths (204). In an aspect, each low resistance path (204) functions as a balancing path which balances the cell voltages of the plurality of cells (102) by dissipating heat in the event of over current or higher cell voltages. In an embodiment, the at least two low resistance resistors is replaced by a single low resistance resistor disposed in each low resistance path (204).
[00071] In an aspect, the plurality of switching units (206) are provided in the current regulating circuit (106). In an embodiment, the plurality of switching units (206) is semiconductor switches. The plurality of switching units (206) are functionally connected to the slave control unit (210) of the control assembly (208). In another aspect, the plurality of switching units (206) are disposed before a low resistance resistor of the at least two low resistance resistors of the plurality of low resistance paths (204) and in series with the low resistance resistor.
[00072] In an aspect, the control assembly (208) comprises one or more control units (210, 212). In another aspect, the first control unit is a master control unit (212) and the second control unit is a slave control unit (210).
[00073] In an aspect, the slave control unit (210) is functionally connected to the plurality of low resistance paths (204), the plurality of high resistance paths (202) and the plurality of switching units (206). In an embodiment, the slave control unit (210) is disposed in one of the junction board (108) or the BMS (104).
[00074] In an aspect, the slave control unit has monitoring and balancing capabilities. The slave control unit is an intelligent unit capable of receiving the output from the balancing circuits and performing logic and control operations. The slave control unit monitors the state of charge (SoC) of the plurality of cells (102) and hence the battery pack (100). The slave control unit (210) also balances the cell voltages in the plurality of cells (102) to ensure longevity of the battery pack (100). In an embodiment, the slave control unit (210) is an application specific integrated circuit.
[00075] In another aspect, the master control unit (212) is functionally connected to the slave control unit (210). In an embodiment, the master control unit (212) is disposed in one of the junction board (108) of the BMS (104). In an aspect, the master control unit (212) is configured to determine start and stop of operations of the battery pack (100) such as charging, discharging and balancing of the plurality of cells (102) and even opening and closing of the plurality of switching units (206). In an embodiment, the master control unit (212) is an application specific integrated circuit.
[00076] In an aspect, the master control unit (212) and the slave control unit (210) are powered by an auxiliary battery to ensure the sanctity of functionality of the master control unit (212) and the slave control unit (210) in the event of any shorting in the battery pack (100).
[00077] In an aspect, a plurality of temperature sensors are disposed in pre-determined local hots spots of the BMS (104). In an aspect, a plurality of temperature sensors are disposed in the BMS to detect any form of misbehaviour occurring in the circuit. The disposition of the plurality of temperature sensors in the BMS is based on localized heating hot spots detected in the BMS during testing phases.
[00078] In operation, the slave control unit (210) is configured to receive the plurality of cell parameters from the plurality of low resistance paths (204) and the plurality of high resistance paths (202), monitor and balance the received plurality of cell parameters in the plurality of low resistance paths (204) and the plurality of high resistance paths (202), and control the plurality of switching units (206) based on configuration received from the master control unit (212). In an aspect, the plurality of cell parameters monitored and balanced by the slave control unit (210) comprises cell voltage and cell current.
[00079] In operation, the master control unit (212) is configured to receive a BMS temperature data from the plurality of temperature sensors, and based on the received BMS temperature data configure the slave control unit (210) to open the plurality of switching units (206) when the BMS temperature data is beyond a pre-defined threshold BMS temperature. The master control unit (212) configures the slave control unit (210) to close the plurality of switching units (206) when the BMS temperature data is less than the pre-defined threshold temperature. Additionally, the master control unit (212) configures the slave control unit (210) to initiate a balancing of cell voltages in the event of detected imbalance in cell voltages.
[00080] Figure 3 illustrates a circuit diagram of the current regulating circuit, in accordance with some embodiments of the present disclosure.
[00081] With reference to Figure 3, C₁, C₂, C₁₃ and C₁₄ denotes each cell of the plurality of cells (102); T₁, T₂ and T₃ denotes a plurality of temperature sensors; D₁₋₁, D₁₋₂, D₂₋₁, D₂₋₂, D₁₃₋₁, D₁₃₋₂, D₁₄₋₁, D₁₄₋₂ denotes a plurality of diodes; Rₕ₁₋₂, Rₕ₂₋₂, Rₕ₁₃₋₁, Rₕ₁₃₋₂ and Rₕ₁₄₋₂ denotes each high resistance resistor disposed in the plurality of high resistance paths (202); Rₗ₁₋₁, Rₗ₁₋₂, Rₗ₂₋₁, Rₗ₂₋₂, Rₗ₁₃₋₁, Rₗ₁₃₋₂, Rₗ₁₄₋₁, Rₗ₁₄₋₂ denotes low resistance resistors disposed in the plurality of low resistance paths (204) and Sₗ, S₂, S₁₃ and S₁₄ denotes switching units disposed in the current regulating circuit (106).
[00082] At the outset, for illustration purposes the battery pack (100) has been depicted to comprise of 14 cells, however the same is merely for illustration and clarity purposes in explanation of the operation of the present subject matter, and the same shall not be construed to limit the applicability of the present disclosure.
[00083] In operation, during functioning of the battery pack (100), shorting may occur at two regions of operation: at the plurality of cells (102) region and at the BMS (104) region. When shorting occurs at the plurality of cells (102) region it may be due to over current or over voltage in the cell connections and may lead to thermal runaway. In case of shorting occurring in BMS (104) region of operation, the tracks of the junction board (108) would burn and open due to high current flowing through these tracks. This is a fail-safe condition which prevents the BMS (104) from being subjected to unintentional high currents. In an embodiment, the tracks are designed to carry a current of 0.5-1 ampere, with over current the tracks will burn.
[00084] In another aspect, when shorting occurs at the BMS (104) region, the BMS (104) is protected against these unintentional high currents by ensuring the current from the plurality of cells (102) flow through the current regulating circuit (106).
[00085] In an aspect, the output of the junction board (108) is first passed through a plurality of high resistance paths (202) and subsequently to a plurality of low resistance paths (204), wherein the plurality of high resistance paths (202) and the plurality of low resistance paths (204) are independent of each other.
[00086] Figure 3 illustrates the circuit layout of the current regulating circuit (106). In the current regulating circuit (106), the cell voltage of each cell of the plurality of cells (102) is first passed through the plurality of high resistance paths (202) and then by the plurality of low resistance paths (204). Each cell (C₁, C₂, C₁₃ and C₁₄) of the plurality of cells (102) is electrically connected to a high resistance path comprising of high resistance resistors (Rₕ₁₋₂, Rₕ₂₋₂, Rₕ₁₃₋₁, Rₕ₁₃₋₂ and Rₕ₁₄₋₂) and a low resistance path comprising of low resistance resistors (Rₗ₁₋₁, Rₗ₁₋₂, Rₗ₂₋₁, Rₗ₂₋₂, Rₗ₁₃₋₁, Rₗ₁₃₋₂, Rₗ₁₄₋₁, Rₗ₁₄₋₂).
[00087] For illustration purposes, cell parameters of C₁ is considered. C₁ denotes a cell of the plurality of cells (102) which is electrically connected to the junction board (108) and post connection to the junction board (108) is connected to the current regulating circuit (106). The cell parameters considered for the purposes of illustration include cell voltage and cell current. As depicted, the cell parameters of C₁ are passed through a high resistance path disposed with a high resistance resistor (Rₕ₁₋₂) and a low resistance path comprising of at least two low resistance resistors (Rₗ₁₋₁, Rₗ₁₋₂) where Rₗ₁₋₁ and Rₗ₁₋₂ are connected in parallel. A diode D₁₋₁ is disposed between Rₗ₁₋₁ and Rₗ₁₋₂. A switching unit Sₗ of the plurality of switching units (206) is disposed in the low resistance path of Rₗ₁₋₂. A temperature sensor (T₃) is disposed in a pre-determined local hot spots so as to effectively detect BMS temperature data in the vicinity of C₁. The electrical connections of C₁ extending from Rₗ₁₋₁, Rₗ₁₋₂, Rₕ₁₋₂ and T₃ are connected to the slave control unit (210). Additionally, the BMS temperature data from the plurality of temperature sensors (T₁, T₂ and T₃) are provided to the master control unit (212).
[00088] In operation, the cell parameters of C₁ are passed through the high resistance path with Rₕ₁₋₂ and the low resistance path with Rₗ₁₋₁ and Rₗ₁₋₂. The high resistance path comprises of a high resistance resistor Rₕ₁₋₂ which impedes the flow of current through it, and prevents any shorting in C₁ to be transmitted to the BMS (104). Thus, the high resistance path with Rₕ₁₋₂ functions as a monitoring circuit for constantly monitoring the cell parameters of C₁ and providing the same to the slave control unit (210). In an embodiment, the high resistance path with high resistance resistor Rₕ₁₋₂ is shared between C₁ and C₂. In an embodiment, each high resistance resistor disposed in the plurality of high resistance path (202) has a resistance of range 100 to 200 ohm.
[00089] Due to the impedance of the high resistance path with Rₕ₁₋₂, the current from C₁ is mandated to flow through the low resistance path with Rₗ₁₋₁ and Rₗ₁₋₂. In the event of imbalance in cell voltage of Cₗ, the low resistance path with Rₗ₁₋₁ and Rₗ₁₋₂ helps in dissipating the over voltage or over current in the form of heat as heat dissipated is dependent on the current flowing through Rₗ₁₋₁ and Rₗ₁₋₂. The low resistance path is provided with at least two low resistance resistor (Rₗ₁₋₁ and Rₗ₁₋₂) which permits the heat dissipation to be distributed between Rₗ₁₋₁ and Rₗ₁₋₂ thus achieving quicker heat dissipation. The low resistance path with Rₗ₁₋₁ and Rₗ₁₋₂ thus functions as a balancing circuit configured to balance the cell voltages of C₁. The low resistance path is connected to the slave control unit (210) which configures the low resistance path with Rₗ₁₋₁ and Rₗ₁₋₂ to balance the cell voltage by passive balancing. Any short permeating through the low resistance path incurs a continuous drainage of charge and results in localized temperature rises at the low resistance resistors (Rₗ₁₋₁ and Rₗ₁₋₂). In an embodiment, each low resistance resistor disposed in the plurality of low resistance paths (204) has a resistance of range 1 to 100 ohm.
[00090] Further, the heat dissipation through Rₗ₁₋₁ and Rₗ₁₋₂ yields local temperature rises which is sensed by the temperature sensor T₃, and T₃ transmits the BMS temperature data to the slave control unit (210) and the master control unit (212). The master control unit (212) compares the received BMS temperature data from T₃ with a pre-defined threshold BMS temperature, and if the BMS temperature data from T₃ exceeds the pre-defined threshold BMS temperature, the master control unit (212) configures the slave control unit (210) to open the switching unit Sₗ, thus disconnecting Cₗ from the BMS (104). Thus, any short occurring in the low resistance path is also isolated by opening of the switching unit Sₗ. In an embodiment, the pre-defined threshold BMS temperature being in a range of 65°C to 95°C.
[00091] In an aspect, when shorting occurs in one of the low resistance path (Rₗ₁₋₁ and Rₗ₁₋₂) there would not be any burning or opening in the low resistance path as the low resistance path is designed to carry such currents. Instead, there would be continuous draining of the battery cell by the low resistance path. In an embodiment, the tracks in the low resistance path are controlled externally so that heat in that local area does not rise.
[00092] Even after opening of the switching unit Sₗ, the cell voltage of Cₗ is continuously monitored by the high resistance path having Rₕ₁₋₂ and the BMS temperature data is monitored by the master control unit (212). The master control unit (212) continuously compares the BMS temperature data with the pre-defined threshold BMS temperature and when the BMS temperature data of T₃ is again less than the pre-defined threshold BMS temperature, the master control unit (212) configures the slave control unit (210) to close the switching unit Sₗ, thus resuming normal functioning of the battery pack (100) through the current regulating circuit (106).
[00093] In an embodiment, the master control unit (212) configures the slave control unit (210) to open the plurality of switches (206) comprising of Sₗ, S₂, S₁₃ and S₁₄ in the current regulating circuit (106), thus yielding a complete halt in charging, discharging, and balancing operations in the current regulating circuit (106).
[00094] In an embodiment, upon a failure of the slave control unit (210), the master control unit (212) receiving the BMS temperature data from the plurality of sensors (T₁, T₂ and T₃) directly operates the plurality of switching units (206) of the current regulating circuit (106) thus protecting the BMS (104) against breakdown of the slave control unit (210).
[00095] In an embodiment, a plurality of diodes (D₁₋₁, D₁₋₂, D₂₋₁, D₂₋₂, D₁₃₋₁, D₁₃₋₂, D₁₄₋₁, D₁₄₋₂) are disposed in the plurality of high resistance paths (202) where each high resistance path (202) is disposed with at least one diode. The plurality of diodes (D₁₋₁, D₁₋₂, D₂₋₁, D₂₋₂, D₁₃₋₁, D₁₃₋₂, D₁₄₋₁, D₁₄₋₂) function as clamping units configured to clamp the cell voltages exceeding a pre-defined value in order to protect the current regulating circuit (106) and the BMS (104). Additionally, unintentional noises developed in the current regulating circuit (106) are dissipated. In an embodiment, the plurality of diodes (D₁₋₁, D₁₋₂, D₂₋₁, D₂₋₂, D₁₃₋₁, D₁₃₋₂, D₁₄₋₁, D₁₄₋₂) are in reverse bias.
[00096] In an embodiment, a plurality of capacitors is disposed in the plurality of low resistance paths (204) and the plurality of high resistance paths (202) of the current regulating circuit (106).
[00097] In an embodiment, a plurality of fusing units are disposed along each of the plurality of low resistance paths (204) of the BMS (104) in series with the low resistance resistors (Rₗ₁₋₁, Rₗ₁₋₂, Rₗ₂₋₁, Rₗ₂₋₂, Rₗ₁₃₋₁, Rₗ₁₃₋₂, Rₗ₁₄₋₁, Rₗ₁₄₋₂). When high current beyond a pre-defined current threshold flows through the plurality of low resistance paths (204) the fusing units are configured to fuse out, thus disconnecting that particular low resistance path from the current regulating circuit (106) and protecting the BMS (104).
[00098] In another embodiment, a plurality of resettable fuses are disposed in one or more low resistance paths of the plurality of low resistance paths (204). In operation, each resettable fuse of the plurality of resettable fuses is configured to increase its resistance based on the increase in current passing through that one or more low resistance path. In the event of an overcurrent occurring, the resistance of each resettable fuse increases which impedes the overcurrent to pass on to the BMS (104). In an embodiment, at least one low resistance resistor and one resettable fuse is disposed along a low resistance path which operate in unison in protecting the BMS (104). The resistance of the resettable fuse again decreases allowing normal flow of current once the high currents are eliminated.
[00099] In another embodiment, a plurality of semiconductor switches are disposed in at least one of the low resistive path of the plurality of low resistance paths (204) of the BMS (104). The semiconductor switches are configured to open and close the current flow paths by the slave control unit (210) under the instruction of the master control unit (212). In an embodiment, the plurality of semiconductor switchers being a mosfet or field effect transistor.
[000100] In an embodiment, a balancing switch control (302) is functionally connected to the master control unit (212). The balancing switch control (302) is configured to externally interfere with the operation of the master control unit (212) with the purpose of allowing external manual intervention in the otherwise automated battery pack. The balancing switch control (302) is configured to externally open or close the plurality of switching units (302) through the master control unit (212).
[000101] In an embodiment, the modules, and sub-modules have been illustrated and explained to serve as examples and should not be considered limiting in any manner. It will be further appreciated that the variants of the above disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications.
[000102] Figure 4 depicts a flowchart illustrating a method performed by a master control unit, in accordance with some embodiments of the present disclosure.
[000103] The method (400) starts at step 402 and proceeds to step 404. At step 404, the master control unit (212) receives a BMS temperature data from a plurality of temperature sensors. The plurality of temperature sensors are disposed in the BMS (104). In an aspect, the plurality of temperature sensors (illustrated as T₁, T₂, T₃ in Figure 3) are disposed in pre-determined local hot spots of the BMS (104) based on testing phases. In an aspect, the master control unit (212) is communicatively connected to the plurality of temperature sensors. In an embodiment, the communication between the master control unit (212) and the plurality of temperature sensors is by one of wireless and wired connection. In an embodiment, wireless connection shall be construed to include cellular, LAN, LIN, CAN, Wi-Fi, Bluetooth, infrared and other forms of communication through electromagnetic signals.
[000104] At step 406, the master control unit (212) compares the BMS temperature data received from the plurality of temperature sensors against a pre-defined threshold BMS temperature. The pre-defined threshold BMS temperature is in a range of 65°C to 95°C. The pre-defined threshold BMS temperature is based on the sphere of application of the battery pack (100) and the operating conditions under which the battery pack (100) is configured to function.
[000105] In an aspect, the master control unit (212) comprises of suitable logic, circuitry, interfaces, and/or code that is configured to receive the BMS temperature data from the plurality of temperature sensors and compare it with the pre-defined threshold BMS temperature. In an embodiment, the master control unit (212) comprises a memory which comprises suitable logic, circuitry, interfaces, and/or code that is configured to store the set of instructions, which may be executed by the master control unit (212). In an embodiment, the memory may be configured to store one or more programs, routines, or scripts that may be executed in coordination with the master control unit (212). The memory may be implemented based on a Random Access Memory (RAM), a Read-Only Memory (ROM), a Hard Disk Drive (HDD), a storage server, and/or a Secure Digital (SD) card.
[000106] At step 406, based on the comparison between the BMS temperature data and the pre-defined threshold BMS temperature, the master control unit (212) configures the slave control unit (210). In an aspect, the master control unit (212) is functionally connected to the slave control unit (210), where the slave control unit (210) under the instruction of the master control unit (212) is configured to operate a plurality of switching units (206). The plurality of switching units (206) is disposed in each of an electrical path of each of a plurality of cells (102) of the battery pack (100). In an embodiment, the plurality of switching units (206) is disposed in the current regulating circuit (106). Based on the compared BMS temperature data and the pre-defined threshold BMS temperature, the method (400) proceeds to either step 410 or step 412. In an aspect, the slave control unit (210) is functionally connected to the plurality of switching units (206). In an embodiment, the communication between the slave control unit (210) and the plurality of switching units (206) is established by one of wireless and wired connection. In an embodiment, wireless connection shall be construed to include cellular, LAN, LIN, CAN, Wi-Fi, Bluetooth, infrared and other forms of communication through electromagnetic signals.
[000107] In an aspect, the master control unit (212) is configured to continuously receive the BMS temperature data from the plurality of temperature sensors for monitoring purposes and continuously compares the BMS temperature data with the pre-defined threshold BMS temperature, to ensure real-time monitoring, diagnosis and coping with unintentional currents in the battery pack (100).
[000108] In an embodiment, the slave control unit (210) and the master control unit (212) are integrated to form a unitary control assembly (208).
[000109] In the event of the BMS temperature data being beyond the pre-defined threshold BMS temperature, the method (400) proceeds to step 410. At step 410, the plurality of switching units (206) are opened by the slave control unit (210) under the instruction of the master control unit (212) to form an open circuit in the current regulating circuit (106). The plurality of switching units (206) are disposed along electrical paths of the current regulating circuit (106) connecting the plurality of cells (102) to the BMS (104), thus the opening of the switching units (206) in the event of overcurrent or over voltage in the plurality of cells (102) manifested as local rises in temperature at pre-determined local hot spots, disconnects the malfunction in the plurality of cells (102) from the BMS (104), protects the BMS (104) against unintentional currents. In an embodiment, the plurality of switching units (206) are semiconductor switches.
[000110] In the event of the BMS temperature data is less than the pre-defined threshold BMS temperature, the method (400) proceeds to step 412. At step 412, the slave control unit (210) configures the plurality of switching units (206) to close, to ensure the current regulating circuit (106) is in closed circuit. The closed position of the plurality of switching units (206) permits resumption of normal operation in the battery pack (100). The closing of the plurality of switching units (206) ensure establishment of secure electrical connection between the plurality of cells (102) and the BMS (104). The method (400) ends at step 414.
[000111] Figure 5 depicts a flowchart for implementation of an exemplary embodiment of the master control unit, in accordance with some embodiments of the present disclosure.
[000112] The flowchart begins at step 502. The flowchart depicted in figure 5 illustrates the intelligence of the master control unit (212) in performing a logical series of operations to ensure safe operational environment of the battery pack (100) comprising of the BMS (104).
[000113] At step 504, corollary to step 404 of figure 4, the master control unit (212) receives the BMS temperature data from the plurality of temperature sensors disposed in pre-determined local hotspots of the BMS (104), wherein the master control unit (212) is communicatively connected to the plurality of temperature sensors.
[000114] At step 506, corollary to step 406 of figure 4, the master control unit (212) compares the BMS temperature data received from the plurality of temperature sensors against a pre-defined threshold BMS temperature. Based on the comparison of the BMS temperature data with the pre-defined threshold BMS temperature, the flowchart proceeds to step 508 or step 510.
[000115] When the BMS temperature data is less than the pre-defined threshold BMS temperature, the flowchart proceeds to step 508, corollary to step 412 of figure 4. At step 507, the plurality of switching units (206) are in turned ON to form a complete circuit for current regulation between the plurality of cells (102) and the BMS (104). In an aspect, Tₘₐₓ illustrated in Figure 5 is the pre-defined threshold BMS temperature. The turning ON of the plurality of switching units (206) is executed by the slave control unit (210) functionally connected to the plurality of switching units (206) under the instruction of the master control unit (212) based on step 506.
[000116] When the BMS temperature data is beyond the pre-defined threshold BMS temperature, the flowchart proceeds to step 510, which is corollary to step 410 of figure 4. In an aspect, Tₘₐₓ illustrated in Figure 5 is the pre-defined threshold BMS temperature. At step 510, the plurality of switching units (206) functionally connected to the slave control unit (210) is turned off, leading to an open circuit between the plurality of cells (102) and the BMS (104). The master control unit (212) configures the slave control unit (210) to operate the plurality of switching units (206).
[000117] At step 512, the BMS temperature data is again compared to the pre-defined threshold BMS temperature (Tₘₐₓ). In the event of the BMS temperature data being beyond the pre-defined threshold BMS temperature (Tₘₐₓ), the flowchart proceeds to step 506 where the BMS temperature data is again compared to the pre-defined threshold BMS temperature (Tₘₐₓ), based on which the plurality of switching units (206) are going to be operated.
[000118] In the event that the BMS temperature data is less than the pre-defined threshold BMS temperature (Tₘₐₓ), a count is generated at step 514.
[000119] At step 516, when the accumulated count is less than the pre-defined value of 10, the plurality of switching units (206) are configured to turn ON by the slave control unit (210) under the instruction of the master control unit (210). The accumulated count being less than the pre-defined value ascertains that the unintentional currents in the current regulating circuit (106) has been suitable diagnosed, and the battery pack (100) can resume its normal functioning.
[000120] At step 516, when the accumulated count exceeds a pre-defined value of 10, the master control unit (212) configures an external unit to appropriately appraise the personnel present in the operating environment of the battery pack (100). In the event of the accumulated count being less than the pre-defined value, no service alert is triggered, and the master control unit (212) continues to monitor and balance the current regulating circuit (106) of the battery pack (100).
[000121] At step 518, a service alert is triggered. In an aspect, the external unit is at least one of an external server, a buzzer, an LED, and a display unit of a vehicle. To this end, the master control unit (212) is communicatively connected to an external server. The external server receives a service alert from the master control unit (212) and transmits the service alert to the concerned authorities. The concerned authorities may include service centres. In another embodiment, the master control unit (212) is communicatively connected to a buzzer disposed external to the battery pack (100) and configured to operate at a pre-defined amplitude to alert the personnel present in the operational environment of the battery pack (100). The communication between the buzzer and the master control unit (212) is established through wired or wireless communication. In another embodiment, the master control unit (212) is communicatively connected to an LED disposed external to the battery pack (100), wherein the LED is configured to illuminate at a pre-defined operating frequency, pre-defined wavelength and a pre-defined intensity of illumination to grab the attention of the personnel. In another embodiment, the battery pack (100) is disposed in a vehicle. The master control unit (212) is communicatively connected to an instrument cluster disposed in the vehicle and is configured to display an alert message on a display unit of the instrument cluster to alert the rider of the vehicle. The flowchart ends at step 520.
[000122] The terms “an embodiment”, “embodiment”, “embodiments”, “the embodiment”, “the embodiments”, “one or more embodiments”, “some embodiments”, and “one embodiment” mean “one or more (but not all) embodiments of the invention(s)” unless expressly specified otherwise. The terms “including”, “comprising”, “having” and variations thereof mean “including but not limited to”, unless expressly specified otherwise. The terms “a”, “an” and “the” mean “one or more”, unless expressly specified otherwise.
[000123] The disclosed claimed limitations and the disclosure provided herein provides a battery pack (100) and a method (400) for current regulation in the battery pack (100) comprising of a current regulating circuit (106) with a control assembly (208) configured to control the monitoring, balancing, charging and discharging of the plurality of cells (102) of the battery pack (100) in protection of the BMS (104) against unintentional circulating currents.
[000124] Thus, the disclosed method and system tries to overcome to technical problem of thermal runaway, unintentional circulating currents, protection of the BMS, alerting concerned authorities in the event of battery pack (100) failure and prevention of shorting occurring in the BMS (104) region and the plurality of cells (102) region in the battery pack (100).
[000125] In an aspect, the unintentional currents are due to shorting occurring either in the BMS (104) or the plurality of cells (102). Shorting may be due to welding connections or interconnector connections in the battery pack (100).
[000126] Due to local temperature rises in the battery pack (100) due to unintentional currents circulating in the battery pack (100), conventional battery packs face an issue of melting of a battery pack top cover due to this overheating and local temperature rises. The disclosed subjected matter addresses this drawback of conventional battery pack by preventing the occurrence of thermal runaway by real-time monitoring and balancing the plurality of cells (102) of the battery pack (100).
[000127] Thus, the claimed limitations overcome the aforementioned technical problems by providing a control assembly (208) comprising of a master control unit (212) and a slave control unit (210) configured to operate a plurality of switching units (206) in the current regulating circuit (106) to prevent the permeation of unintentional currents to the BMS (104).
[000128] In light of the above-mentioned advantages and the technical advancements provided by the disclosed method and system, the claimed steps as discussed above are not routine, conventional, or well understood in the art, as the claimed steps enable the following solutions to the existing problems in conventional technologies. Further, the claimed steps clearly bring an improvement in the functioning of the device itself as the claimed steps provide a technical solution to a technical problem.
[000129] A description of an embodiment with several components in communication with a other does not imply that all such components are required, On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the invention,
[000130] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter and is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
[000131] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
[000132] The present disclosure may be realized in hardware, or a combination of hardware and software. The present disclosure may be realized in a centralized fashion, in at least one computer system, or in a distributed fashion, where different elements may be spread across several interconnected computer systems, a computer system or other apparatus adapted for carrying out the methods described herein may be suited. A combination of hardware and software may be a general-purpose computer system with a computer program that, when loaded and executed, may control the computer system such that it carries out the methods described herein. The present disclosure may be realized in hardware that comprises a portion of an integrated circuit that also performs other functions.
[000133] A person with ordinary skills in the art will appreciate that the systems, modules, and sub-modules have been illustrated and explained to serve as examples and should not be considered limiting in any manner. It will be further appreciated that the variants of the above disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications.
[000134] Those skilled in the art will appreciate that any of the aforementioned steps and/or system modules may be suitably replaced, reordered, or removed, and additional steps and/or system modules may be inserted, depending on the needs of a particular application. In addition, the systems of the aforementioned embodiments may be implemented using a wide variety of suitable processes and system modules, and are not limited to any particular computer hardware, software, middleware, firmware, microcode, and the like. The claims can encompass embodiments for hardware and software, or a combination thereof.
[000135] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.
List of Reference Numerals:
100 – A Battery Pack
102 – Plurality of Battery Cells
104 – Battery Management System
106 – Junction Board
202 – Plurality of Temperature Sensors
204 – Plurality of High Resistance Paths
206 – Plurality of Low Resistance Paths
208 – Plurality of Switching Means
210 – Slave Control Unit
212 – Master Control Unit
302 – Balancing switch control
, Claims:We claim:
1. A battery pack (100), the battery pack (100) comprising:
a plurality of cells (102);
a battery management system (BMS) (104);
a current regulating circuit (106), the current regulating circuit (106) comprises
a plurality of high resistance paths (202), the plurality of high resistance paths (202) being electrically connected to the plurality of cells (102);
a plurality of low resistance paths (204), the plurality of low resistance paths (204) being electrically connected to the plurality of cells (102);
a plurality of switching units (206); and
a control assembly (208), the control assembly (208) comprises one or more control units, wherein a first control unit being a master control unit (212) and a second control unit being a slave control unit (210),
wherein the slave control unit (210) being functionally connected to the plurality of low resistance paths (204), the plurality of high resistance paths (202) and the plurality of switching units (206), and
wherein the master control unit (212) being functionally connected to the slave control unit (210).
2. The battery pack (100) as claimed in claim 1, wherein the battery pack (100) comprises a junction board (108), wherein the junction board (108) being disposed between the plurality of cells (102) and the BMS (104).
3. The battery pack (100) as claimed in claim 2, wherein the master control unit (212) being disposed in one of the junction board (108) or the BMS (104).
4. The battery pack (100) as claimed in claim 2, wherein the slave control unit (210) being disposed in one of the junction board (108) or the BMS (104).
5. The battery pack (100) as claimed in claim 1, wherein a plurality of temperature sensors being disposed in pre-determined local hot spots of the BMS (104).
6. The battery pack (100) as claimed in claim 2, wherein the BMS (104) being configured to monitor a plurality of cell parameters of the plurality of cells (102), wherein the plurality of cells (102) being electrically connected to the BMS (104) through the junction board (108).
7. The battery pack (100) as claimed in claim 6, wherein
the junction board (108) being electrically connected to each of the plurality of cells (102) to receive the plurality of cell parameters from the plurality of cells (102); and wherein
the junction board (108) provides the received plurality of cell parameters to the BMS (104) using a single connector.
8. The battery pack (100) as claimed in claim 6, wherein the plurality of cell parameters include at least one of a state of charge, a state of health, cell current, cell voltage, cell temperature of each of the plurality of cells.
9. The battery pack (100) as claimed in claim 5, wherein the master control unit (212) being configured to
receive a BMS temperature data from the plurality of temperature sensors;
configure the slave control unit (210) to open the plurality of switching units (206) when the BMS temperature data being beyond a pre-defined threshold BMS temperature.
10. The battery pack (100) as claimed in claim 8, wherein the slave control unit (210) being configured to
receive the plurality of cell parameters from the plurality of low resistance paths (204) and the plurality of high resistance paths (202);
monitor and balance the received plurality of cell parameters in the plurality of low resistance paths (204) and the plurality of high resistance paths (202); and
control the plurality of switching units (206) based on configuration received from the master control unit (212).
11. The battery pack (100) as claimed in claim 9, wherein the master control unit (212) configures the slave control unit (210) to close the plurality of switching units (206) when the BMS temperature data being less than the pre-defined threshold temperature.
12. The battery pack (100) as claimed in claim 10, wherein the plurality of cell parameters monitored and balanced by the slave control unit (210) comprising the cell voltage and the cell current.
13. The battery pack (100) as claimed in claim 1, wherein the plurality of switching units (206) being semiconductor switches.
14. The battery pack (100) as claimed in claim 1, wherein the current regulating circuit (106) being disposed in one of the junction board (108) or the BMS (104).
15. The battery pack (100) as claimed in claim 1, wherein each high resistance path (202) of the plurality of high resistance paths (202) being disposed with at least one high resistance resistor and wherein each high resistance path (202) being configured to be electrically connected to at least two adjacent cells of the plurality of cells (102).
16. The battery pack (100) as claimed in claim 1, wherein each low resistance path (204) of the plurality of low resistance paths (204) being disposed with at least two low resistance resistors wherein the two low resistance resistors being configured to be connected in parallel to each other in each of the low resistance paths (204).
17. The battery pack (100) as claimed in claim 16, wherein the plurality of switching units (206) being disposed before a low resistance resistor disposed in the plurality of low resistance paths (204).
18. The battery pack (100) as claimed in claim 1, wherein a plurality of diodes being disposed in the plurality of high resistance paths (202) wherein each high resistance path (202) being disposed with at least one diode.
19. The battery pack (100) as claimed in claim 1, wherein a plurality of fusing units being disposed in one or more low resistance paths (204) of the plurality of low resistance paths (204).
20. The battery pack (100) as claimed in claim 1, wherein a plurality of resettable fuses being disposed in the one or more low resistance paths (204) of the plurality of low resistance paths (204).
21. A method (400) for regulating currents in a battery pack (100), wherein the method comprises steps
receiving, by a master control unit (212), a BMS temperature data from a plurality of temperature sensors,
wherein the plurality of temperature sensors being disposed in a BMS (104);
comparing, by the master control unit (212), the BMS temperature data with a pre-defined threshold BMS temperature; and
configuring, by the master control unit (212), a slave control unit (210) to
open a plurality of switching units (206) when the BMS temperature data being beyond the pre-defined threshold BMS temperature,
wherein the plurality of switching units (206) being disposed in each of an electrical path of each of a plurality of cells (102) of the battery pack (100), and
close the plurality of switching units (206) when the BMS temperature data being less than the pre-defined threshold BMS temperature.
22. The method (400) for regulating currents in the battery pack (100) as claimed in claim 21, wherein the plurality of cells (102) of the battery pack (100) being electrically connected to the BMS (104).
23. The method (400) for regulating currents in the battery pack (100) as claimed in claim 21, wherein the master control unit (212) being configured to trigger a service alert when the sensed BMS temperature data being continuously beyond the pre-defined threshold BMS temperature over a pre-defined threshold time period.