Claims:WE CLAIM:
1. A system (100) for connecting a plurality of modules (102, 104) characterized in having a single Battery Management System (BMS) (302), wherein the plurality of modules (102, 104) is connected in a series configuration.
2. The system (100) as claimed in claim 1, wherein the plurality of modules (102, 104) includes a plurality of cells connected with each other.
3. The system (100) as claimed in claim 1 and 2, wherein the plurality of cells is connected to the Battery Management System (BMS) (302).
4. The system (100) as claimed in claim 1, wherein the plurality of modules (102, 104) is connected through a power connector (110) and a sensor cable connector (112).
5. The system (100) as claimed in claim 1, wherein the number of modules is three in number (102, 104a, 104b).
6. The system (100) as claimed in claim 1, wherein the number of modules is two in number.
7. The system (100) as claimed in claim 1 monitors the voltage balance between the plurality of modules (102, 104).
8. A method (500) of assembling a plurality of modules (102, 104) having a single Battery Management System (BMS) (302), the method (500) comprises:
- switching OFF a POWER button (106) to turn off the power supply to the plurality of modules (102, 104), wherein the plurality of modules (102, 104) include a lower module (102) and an upper module (104);
- connecting the plurality of modules (102, 104) in a series configuration through a power connector (110) to provide a reference base voltage to the upper module (104);
- connecting the plurality of modules (102, 104) through a sensor cable connector (112) to provide cell voltage and temperature of a plurality of cells to the Battery Management System (BMS) (302); and
- switching ON the POWER button (106) to start the power supply to the plurality of modules (102, 104).
9. The method (500) of assembling as claimed in claim 8, wherein the lower module (102) includes a Battery Management System (BMS) (302).
10. The method (500) of assembling as claimed in claim 8, wherein the cells of the lower module (102) is connected to the Battery Management System (BMS) (302) prior to the cells of the upper module (104).
11. The method (500) of assembling as claimed in claim 8, wherein the plurality of modules (102, 104) are connected to a charger/load through an output unit (108).
12. A method (600) of disassembling a plurality of modules (102, 104) having a single Battery Management System (BMS) (302), the method (600) comprises:
- disconnecting a charger/load connected to the plurality of modules (102, 104);
- switching OFF a POWER button (106) to turn off the power supply to the plurality of modules (102, 104), wherein the plurality of modules (102, 104) include a lower module (102) and an upper module (104);
- removing a sensor cable connector (112) to avoid detection of an abnormality in the Battery Management System (BMS) (302); and
- removing a power connector (110) to separate the plurality of modules (102, 104).
13. The method (600) of disassembling as claimed in claim 12, wherein the plurality of modules (102, 104) are connected in a series configuration.
14. The method (600) of disassembling as claimed in claim 12, wherein removal of the sensor cable connector (112) first and ensuring that the power connector (110) is intact to avoid the abnormality.
, Description:FIELD OF INVENTION
The present embodiment relates to a battery pack design for an electrical vehicle, and more particularly relates to a system and a method for assembling and disassembling a plurality of modules of the battery pack.
BACKGROUND OF INVENTION
The increasing number of vehicles on road has put a strain on the fossil fuel such as diesel and petrol. Therefore, there is a need for vehicles that can run on alternate fuels. The electrical vehicles that run on electrical energy have gained a major interest in recent times.
The battery packs have increased weight and higher volume as the capacity increases. For example, two-wheeled electrical vehicles tend to have a battery pack with lesser weight and volume as compared to three-wheeled electrical vehicles. The weight of the battery pack depends on the capacity of the battery pack and requirement of the user. For a 3kWh battery pack with NMC or LFP chemistry, the weight ranges between 50-60 kilograms. The weight of the battery pack makes it difficult to carry the battery pack from one place to another. The limitations of weight elicit a need for dividing the battery pack into multiple modules for the easy transportation.
Further, during the swappable applications, such as when swapping a discharged battery pack in the three-wheeled electrical vehicles or the two-wheeled electrical vehicles with a freshly charged battery pack, there is a constraint of space. Therefore, there is a need to connect the modules in a series configuration while maintaining the voltage balance in the battery pack.
The battery packs typically include a plurality of battery cells that may be arranged in series or in parallel to provide a desired voltage or current capacity. There are many prior arts that suggest the bifurcation of the cell of the battery packs into multiple modules. Each of the modules (arranged in series) has a specific Battery Management System (BMS) arranged in a master slave configuration. The disadvantages associated with such arrangement include higher cost of multiple Battery Management Systems (BMS) and lack of voltage balance in the multiple modules.
Therefore, there is a need of a system and method for assembling and disassembling a plurality of modules with a single Battery Management Systems (BMS). There is also a need of a system that effectively regulates/monitors the voltage balance in the plurality of modules (arranged in series).
SUMMARY OF THE INVENTION
In an aspect, a system for connecting a plurality of modules having a single Battery Management System (BMS) is provided. The plurality of modules is connected in a series configuration through special connectors such as a power connector and a sensor cable connector. The system monitors and controls the voltage balance between the plurality of modules through the single Battery Management System (BMS).
In another aspect, a method of assembling a plurality of modules having a single Battery Management System (BMS) is provided. The method includes the following steps: 1) Switching OFF a POWER button to turn off the power supply to the plurality of modules. The plurality of modules includes an upper module and a lower module. 2) Connecting the plurality of modules through a power connector to provide a reference base voltage to the upper module. The plurality of modules is arranged/connected in a series configuration. 3) Connecting the plurality of modules through a sensor cable connector to provide cell voltage of a plurality of cells to an integrated circuit. 4) Switching ON the POWER button to start the power supply to the plurality of modules. The output is provided/achieved on the lower module.
In yet another aspect, a method of disassembling a plurality of modules having a single Battery Management System (BMS) is provided. The method includes the following steps: 1) Disconnecting a charger/load connected to the plurality of modules. 2) Switching OFF a POWER button to turn off the power supply to the plurality of modules. The plurality of modules includes an upper module and a lower module. 3) Removing a sensor cable connector to avoid detection of an abnormality in the Battery Management System (BMS). 4) Removing a power connector to separate the plurality of modules.
The preceding is a simplified summary to provide an understanding of some aspects of embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and still further features and advantages of embodiments of the present invention will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, and wherein:
Figure 1 illustrates a system (100) for connecting a plurality of modules, according to an embodiment herein;
Figure 2 illustrates a schematic representation for connecting a plurality of cells of the plurality of modules, according to an embodiment herein;
Figure 3 illustrates a detailed representation of the system for connecting two modules including power and sensor cable connections, according to an embodiment herein;
Figure 4 illustrates a detailed representation of the system for connecting three modules including power and sensor cable connections, according to an embodiment herein;
Figure 5 illustrates a method (500) of assembling the plurality of modules, according to an embodiment herein; and
Figure 6 illustrates a method (600) of disassembling the plurality of modules, according to an embodiment herein.
To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures.
DETAILED DESCRPTION
As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to.
The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.
Figure 1 illustrates the system (100) for connecting the plurality of modules (102, 104) of a battery pack in a series configuration. The system (100) helps in connecting the plurality of modules (102, 104) through a single Battery Management System (BMS) (302).
In an embodiment, the battery pack is a battery storage unit installed in an electrical vehicle. In an embodiment, the battery pack is capable of storing the power/energy in the form of electrical energy. In an embodiment, the battery pack supply power to an electrical motor or take in the power from the regenerative electrical braking system of the electrical vehicles.
In an embodiment, the battery pack is a battery such as, but not limited to, lithium-ion battery, nickel-zinc battery, nickel metal hydride, nickel-cadmium battery and solid state battery. In a preferred embodiment, the battery is a lithium-ion battery of various lithium-ion chemistries such as, but not limited to, LFP (Lithium Ferro Phosphate), NMC (Nickel Manganese Cobalt), LTO (Lithium Titanate Oxide) and LMO (Lithium Manganese Oxide).
The battery pack includes a plurality of cells connected with each other in series/parallel. In an embodiment, the plurality of cells is connected through a special connector. In an embodiment, the number of cells in the battery pack depends on the capacity of the battery pack and the requirement of the user.
The weight of the battery pack depends on the capacity of the battery pack and requirement of the user. For example, the weight of a 3kWh battery pack with NMC or LFP chemistry ranges between 50-60 kilograms. The weight of the battery pack makes it difficult to transfer/carry the battery from one place to another. Therefore, the plurality of cells of the battery pack is divided into the plurality of modules (102, 104). In an embodiment, the battery pack is divided into two modules (102, 104). In another embodiment, the battery pack is divided into three modules (shown in figure 4). In an embodiment, the three modules include a first module (102) and the second module (104) that is further divided into two modules (104a, 104b). In a preferred embodiment, the battery pack is divided into two modules (102, 104) so that both the modules have the similar size and weight. In an embodiment, the plurality of modules (102, 104) or (102, 104a, 104b) is placed inside a housing and can be placed either on top of each other or side-by-side to each other.
The plurality of modules (102, 104) or (102, 104a, 104b) is connected in a series configuration (shown in figure 2). The arrangement of the modules in the series configuration is not explained in the description as it is very well known to the person skilled in the art. In an embodiment, the plurality of modules is termed as “module 1” (102) and “module 2” (104). In another embodiment, the plurality of modules is termed as “lower module” (102) and the “upper module” (104).
The “module 1” or the “lower module” (102) has an electrical switch or a POWER button (106) for supplying current/power to the plurality of modules (102, 104). The plurality of modules (102, 104) is connected to a charger/load through an output unit (108). The output unit (108) is present at the “module 1” or the “lower module” (102).
The plurality of modules (102, 104) is connected to the single Battery Management System (BMS) (302). In an embodiment, the Battery Management System (BMS) (302) monitors the plurality of modules (102, 104). In an embodiment, the Battery Management System (BMS) (302) monitors the temperature, voltage and the power supply to the plurality of modules (102, 104). In an embodiment, the Battery Management System (BMS) (302) detects an abnormality in the plurality of modules (102, 104). In an embodiment, the Battery Management System (BMS) (302) monitors a State of Charge (SoC) and a State of Health (SoH) of the battery pack in the plurality of modules.
The Battery Management System (BMS) (302) manages the battery pack by protecting the battery from operating outside the safe operating temperature, voltage and current.
In an embodiment, the Battery Management System (BMS) (302) includes an electrical printed circuit board with an active microcontroller. In an embodiment, the plurality of cells is connected to the electrical printed circuit board. In an embodiment, the cells of the plurality of modules (102, 104) are connected to the single Battery Management System (BMS) (302). In an embodiment, the Battery Management System (BMS) (302) is present in the “module 1” or the “lower module” (102).
The plurality of modules (102, 104) is connected through a power connector (110) and a sensor cable connector (112). The plurality of cells is connected to the Battery Management System (BMS) (302) through the power connector (110) and the sensor cable connector (112). The plurality of cells is connected to each other through the power connector (110). The plurality of cells is connected to the Battery Management System (BMS) (302) through the sensor cable connector (112).In an embodiment, the plurality of modules (102, 104) is connected through a male connector and a female connector.
The power connector (110) ensures that the “module 2” or “upper module” (104) gets the reference base voltage through the wire that is connecting between cell 7 and cell 8 (shown in figure 3) for the 16-cell in series configuration shown in figure 3. Similarly for a 14 cell in series configuration, the reference base voltage through the wire shall be connected between cell 6 and cell 7. The sensor cable connector (112) helps in recording voltage of the plurality of cells in the circuit and also temperature, via temperature sensors attached to the cells, of the plurality of cells in the circuit. The sensor cable connector (112) is a multi-pin connector that connects multiple wires.
In an embodiment, the plurality of cells is connected simultaneously to the Battery Management System (BMS) (302). In another embodiment, the cells of the “module 1” or the “lower module” (102) is connected first followed by the plurality of cells of the “module 2” or “upper module” (104).
The Battery Management System (BMS) (302) remains inactive when the plurality of modules (102, 104) is not connected to each other. In an embodiment, the Battery Management System (BMS) (302) does not allow charging/discharging of the separate/individual modules. In an embodiment, the Battery Management System (BMS) (302) allows the charging/discharging when the plurality of modules (102. 104) are connected to form the battery pack.
The Battery Management System (BMS) (302) is activated when the plurality of modules (102, 104) is connected to each other through the power connector (110) and the sensor cable connector (112). The Battery Management System (BMS) (302) allows the charging/discharging of the battery pack. The Battery Management System (BMS) (302) maintains/monitors the voltage balance between the plurality of modules (102, 104).
Figure 5 illustrates the method (500) of assembling the plurality of modules (102, 104) in the series configuration. The plurality of modules (102, 104) is assembled to form a single battery pack with a single Battery Management System (BMS) (302). The method (500) includes the following steps:
At step 502, the POWER button (106) is switched OFF to turn off the power supply to the plurality of modules (102, 104). In an embodiment, the number of modules (102, 104) is two in number (shown in figure 3). In another embodiment, the number of modules (102, 104) is three in number (shown in figure 4). In an embodiment, the three modules include a first module (102) and the second module (104) that is further divided into two modules (104a, 104b). In a preferred embodiment, the number of modules (102, 104) is two in number so that both the modules have the similar size and weight. In an embodiment, the plurality of modules (102, 104) has equal number of cells.
In an embodiment, the plurality of modules is termed as “module 1” (102) and “module 2” (104). In another embodiment, the plurality of modules is termed as “lower module” (102) and the “upper module” (104).
The “module 1” or the “lower module” (102) has an electrical switch or a POWER button (106) for supplying current/power to the plurality of modules (102, 104). In an embodiment, the POWER button (106) is turned OFF to stop the power supply to the plurality of modules (102, 104). In an embodiment, the POWER button (106) is turned OFF to prevent any communication between a host controller in the battery management system (BMS) and other peripherals.
At step 504, the plurality of modules (102, 104) is connected through the power connector (110). In an embodiment, the power connector (110) connects the plurality of cells with each other. The power connector (110) ensures that the “module 2” or “upper module” (104) gets the reference base voltage through the wire that is connecting between cell 7 and cell 8 (shown in figure 3).
In an embodiment, the plurality of cells is connected with each other in series/parallel. In an embodiment, the number of cells in the battery pack depends on the capacity of the battery pack and on requirement of the user.
In an embodiment, the plurality of cells (of Module 1 and Module 2) is connected with the Battery Management System (BMS) (302). In an embodiment, the Battery Management System (BMS) (302) monitors the plurality of modules (102, 104). In an embodiment, the Battery Management System (BMS) (302) monitors the temperature, voltage and the power supply to the plurality of modules (102, 104). In an embodiment, the Battery Management System (BMS) (302) detects any abnormality in the plurality of modules (102, 104). In an embodiment, the Battery Management System (BMS) (302) monitors a State of Charge (SoC) and a State of Health (SoH) of the electrical vehicles.
The Battery Management System (BMS) (302) manages the battery pack by protecting the battery from operating outside the safe operating temperature, voltage and current.
In an embodiment, the plurality of cells of the plurality of modules (102, 104) is simultaneously connected to the Battery Management System (BMS) (302). In an embodiment, the cells of the “lower module” or “module 1” (102) are connected first followed by the cells of the “upper group” or “module 2” (104).
In an embodiment, the power connector (110) is connected prior to the sensor cable connector (112). The sensor cable connector (112) when connected prior to the power connector (110) does not give a reference base voltage to the Battery Management System (BMS) (302) and the system (100) will not boot efficiently.
At step 506, the plurality of modules (102, 104) is connected through the sensor cable connector (112) to provide cell voltage and temperature of the plurality of cells to an electrical printed circuit board of the Battery Management System (BMS) (302). The sensor cable connector (112) helps in connecting/relaying voltage and temperature of the plurality of cells in the circuit. The sensor cable connector (112) is a multi-pin connector that helps in connecting multiple wires.
In an embodiment, the sensor cable connector (112) allows the Battery Management System (BMS) (302) to monitor the cell voltage and cell temperature of the plurality of cells. In an embodiment, the Battery Management System (BMS) (302) monitors and corrects the voltage imbalance in the plurality of modules (102, 104).
At step 508, the POWER button (106) is switched ON to turn on the power supply to the plurality of modules (102, 104). In an embodiment, the power supply helps in activating the Battery Management System (BMS) (302). In an embodiment, the Battery Management System (BMS) (302) allows the charging/discharging of the plurality of modules (102, 104). In an embodiment, the power supply allows the communication between the host controller and other peripherals. The plurality of modules (102, 104) is connected to a charger/load through an output unit (108). The output unit (108) is present at the “module 1” or the “lower module” (102).
Figure 6 illustrates the method (600) of disassembling the plurality of modules (102, 104) that are connected in the series configuration. In an embodiment, the plurality of modules (102, 104) is connected to have the single Battery Management System (BMS) (302). The method (600) includes the following steps:
At step 602, a charger/load is removed from the plurality of modules (102, 104). In an embodiment, the charger/load is removed to avoid any abnormality in the plurality of modules (102, 104). In an embodiment, the charger/load is removed so that the battery pack is first isolated.
At step 604, the POWER button (106) is switched OFF to turn off the power supply to the plurality of modules (102, 104). In an embodiment, the number of modules (102, 104) is two in number (shown in figure 3). In another embodiment, the number of modules (102, 104) is three in number (shown in figure 4). In an embodiment, the three modules include a first module (102) and the second module (104) that is further divided into two modules (104a, 104b).In a preferred embodiment, the number of modules (102, 104) is two in number so that both the modules have the similar size and weight.
In an embodiment, the plurality of modules is termed as “module 1” (102) and “module 2” (104). In another embodiment, the plurality of modules is termed as “lower module” (102) and the “upper module” (104).
The “module 1” or the “lower module” (102) has an electrical switch or a POWER button (106) for supplying current/power to the plurality of modules (102, 104). In an embodiment, the POWER button (106) is turned OFF to stop the power supply to the plurality of modules (102, 104). In an embodiment, the POWER button (106) is turned OFF to prevent any communication between a host controller in the battery management system (BMS) and other peripherals.
At step 606, the sensor cable connector (112) is removed from the plurality of modules (102, 104). The sensor cable connector (112) is a multi-pin connector that helps in connecting multiple wires. In an embodiment, the connection between the plurality of modules (102, 104) and the Battery Management System (BMS) (302) is removed.
In an embodiment, the sensor cable connector (112) is removed prior to the power connector (110) so that the reference base voltage to the Battery Management System (BMS) (302) remains intact. In an embodiment, the sensor cable connector (112) is removed to avoid detection of an abnormality in the Battery Management System (BMS) (302).
At step 608, the power connector (110) is removed from the plurality of modules (102, 104). In an embodiment, the power connector (110) separates the plurality of modules (102, 104). In an embodiment, the separated modules cannot be further charged/ discharged.
The method of assembling (500) and disassembling (600) the plurality of modules (102, 104) has to be performed in a systematic flow so as to avoid any abnormality. The method of assembling (500) and disassembling (600) also helps in maintaining/monitoring the voltage balance in the plurality of modules (102, 104).
The foregoing discussion of the present invention has been presented for purposes of illustration and description. It is not intended to limit the present invention to the form or forms disclosed herein. In the foregoing Detailed Description, for example, various features of the present invention are grouped together in one or more embodiments, configurations, or aspects for the purpose of streamlining the disclosure. The features of the embodiments, configurations, or aspects may be combined in alternate embodiments, configurations, or aspects other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention the present invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of the present invention.
Moreover, though the description of the present invention has included description of one or more embodiments, configurations, or aspects and certain variations and modifications, other variations, combinations, and modifications are within the scope of the present invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments, configurations, or aspects to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.