Configurable battery pack for fast charging

Abstract

A configurable battery system can be arranged in such a way that two battery modules are connected in parallel to achieve a target maximum voltage for a load, or in series to achieve a high voltage of about twice the target maximum voltage. Fast charging at a high voltage can allow both battery modules to be charged at a charging current close to the expected maximum current of the battery charger. The battery management module determines a switch configuration to couple the battery modules in series or in parallel. The battery management module applies the switch configuration to one or more switches to manage the charging of the battery modules. The battery management module can receive charger capability information, local charging information, and fault information to help determine the switch configuration.

Description

Technical Field

[0001] The present disclosure is directed to configurable batteries that provide improved charging and operation.This application claims priority to U.S. Provisional Patent Application No. 62 / 578,500 filed on October 29, 2017 and U.S. Patent Application No. 16 / 004,258 filed on June 8, 2018, the disclosures of which are incorporated herein by reference in their entirety. Background Art

[0002] Battery chargers and their accompanying electrical components (e.g., cables and charging inlets) typically have current limitations. To achieve higher charging currents from the battery charger (e.g., during fast charging), large DC fast charging cables are typically required. Battery chargers also typically have a maximum limit on the supply voltage. For example, SAE J1772 targets 900V and 400A for the maximum output of a typical DC fast charger for electric vehicles. To increase the charging rate, the current carrying capacity of the electronics, components, and leads typically needs to be increased to handle the higher currents, and the heat dissipation capacity also needs to be increased. For example, ohmic heating increases with the square of the current. Thus, it would be advantageous to increase the charging rate without requiring components with higher current ratings.

[0003] Furthermore, battery operated devices (e.g., electric vehicles) typically use components (e.g., AC compressors, PTC heaters, drive units, etc.) that are designed to operate at maximum voltage levels. Battery operated devices also typically need to be able to operate while charging. Thus, it would be advantageous to increase the charging rate without increasing the voltage applied to the load of the battery operated device.

[0004] A battery system typically also includes more than one battery module. If a fault occurs in a battery module, then the entire battery system may need to be disconnected from the load. Thus, it would be advantageous to manage the occurrence of a fault in a battery module without having to disconnect the load or having a different voltage applied to the load. Summary of the invention

[0005] A configurable battery system according to the present disclosure includes a first battery module and a second battery module, wherein each battery module includes a positive terminal and a negative terminal. The configurable battery system also includes at least one switch having at least two poles. In a high voltage configuration of at least one switch, the first battery module and the second battery module are connected in series. In a low voltage configuration of at least one switch, the first battery module and the second battery module are connected in parallel.

[0006] In some embodiments, at least one switch includes a first single-pole double-throw (SPDT) switch and a second SPDT switch. In a high voltage configuration, the first SPDT switch and the second SPDT switch are both in a first switch position, thereby connecting the positive terminal of the first battery module to the negative terminal of the second battery module. In a low voltage configuration, the first SPDT switch is in a second switch position, thereby connecting the negative terminal of the first battery module to the negative terminal of the second battery module. Additionally, in a low voltage configuration, the second SPDT switch is in a second switch position, thereby connecting the positive terminal of the first battery module to the positive terminal of the second battery module.

[0007] In some embodiments, at least one switch includes two single-pole single-throw (SPST) switches. In a high voltage configuration, a first of the two SPST switches is in an off position and a second of the two SPST switches is in an on position, thereby connecting the positive terminal of the first battery module to the negative terminal of the second battery module. In a low voltage configuration, a first of the two SPST switches is in an on position, thereby connecting the negative terminal of the first battery module to the negative terminal of the second battery module, and a second of the two SPST switches is in an off position.

[0008] In some embodiments, the configurable battery system includes at least one charger switch configured to connect and disconnect the first and second battery modules to and from the charger. For example, the at least one charger switch may include a SPST contactor for connecting and disconnecting the charger.

[0009] In some embodiments, in the high voltage configuration, the positive terminal of the equipment load is connected to the positive terminal of the first battery module, and the negative terminal of the equipment load is connected to the negative terminal of the first battery module.For example, the equipment load may include any system or subsystem of an electric vehicle.

[0010] In some embodiments, the configurable battery system includes at least one load switch having at least two poles. In a high voltage configuration, when the at least one load switch is set to one or more first switch positions, the positive terminal of the device load is connected to the positive terminal of the first battery module, and the negative terminal of the device load is connected to the negative terminal of the first battery module. In addition, in a high voltage configuration, when the at least one load switch is set to one or more second switch positions, the positive terminal of the device load is connected to the positive terminal of the second battery module, and the negative terminal of the device load is connected to the negative terminal of the first battery module.

[0011] In some embodiments, a configurable battery system includes control circuitry configured to, when in a high voltage configuration, set a position of at least one load switch based on status information of a first battery module, a second battery module, or both.

[0012] In some embodiments, the configurable battery system is configured for use in an electric vehicle, and in the high voltage configuration, the configurable battery charging system is configured to receive a charging voltage of 900 volts (V). In some embodiments, in the charging configuration, the configurable battery charging system is configured to provide a voltage of 450 V to components of the electric vehicle. In some embodiments, the configurable battery system includes a battery management module configured to select between a low voltage configuration and a high voltage configuration.

[0013] In some embodiments, a battery management module manages battery charging of a first battery module and a second battery module coupled in series. The battery management module uses at least one switch in a first switch configuration to couple an electrical load in parallel to the first battery module during charging. The battery management module determines a first battery characteristic of the first battery module and a second battery characteristic of the second battery module during charging. The battery management module determines to apply a second switch configuration to at least one switch based on the first battery characteristic and the second battery characteristic. The second switch configuration couples the electrical load in parallel to the second battery module during charging. The battery management module applies the second switch configuration to at least one switch.

[0014] In some embodiments, the first battery characteristic comprises a first voltage across a positive terminal and a negative terminal of the first battery module, and the second battery characteristic comprises a second voltage across a positive terminal and a negative terminal of the second battery module. In some embodiments, the battery management module determines to apply a second switch configuration to at least one switch based on a difference between the first voltage and the second voltage.

[0015] In some embodiments, the first battery characteristic includes a first cumulative time that the first battery module is coupled to the electrical load, and the second battery characteristic includes a second cumulative time that the second battery module is coupled to the electrical load. For example, the cumulative time that the battery is coupled to the electrical load can provide a convenient way to use the battery modules equally during charging. In another example, the battery management module determines the difference between the first cumulative time and the second cumulative time.

[0016] In some embodiments, the battery management module determines local charging information, which may include a preference for charging at a high voltage. In some embodiments, the battery management module determines to couple the first battery module and the second battery module in series based at least in part on the local charging information. For example, if the battery charger is capable of fast charging (e.g., high voltage charging), the battery management module determines to couple the first battery module and the second battery module in series.

[0017] In some embodiments, the battery management module identifies whether a fault has occurred in the first battery module, the second battery module, or both. In some such embodiments, the battery management module also determines to apply a second switch configuration to at least one switch based at least in part on whether a fault has occurred.

[0018] In some embodiments, the battery management module applies a pre-charge configuration to the at least one switch to reduce the inrush current when the second load switch configuration is applied to the at least one switch. For example, the pre-charge configuration may include connecting a circuit having a capacitor and a resistor to reduce a voltage difference across the at least one switch before changing the position of the at least one switch.

[0019] In some embodiments, the battery management module determines the time that has passed since the last change in the switch configuration. In some such embodiments, the battery management module determines to apply the second switch configuration based at least in part on the elapsed time. For example, if the determined elapsed time is above a threshold, the battery management module may determine to connect the electrical load to another battery module to balance usage.

[0020] In some embodiments, a battery management module manages a fault in a battery system, the battery system comprising a plurality of battery modules and at least one switch. When at least one switch is in a first switch configuration, the battery management module identifies the occurrence of a fault in a battery module among the plurality of battery modules. The first switch configuration couples the plurality of battery modules in parallel with each other and with an electrical load. The battery management module determines a second switch configuration in response to identifying the occurrence of a fault, and applies the second switch configuration to at least one switch. The second switch configuration decouples the battery module in which the fault has occurred from the electrical load, and couples the remaining one or more battery modules in the plurality of battery modules that have not failed to the electrical load. Thus, the electrical load can, for example, continue to receive power during the occurrence of the fault. In some cases, the occurrence of the fault corresponds to an open circuit within the battery module. In some cases, the occurrence of the fault corresponds to a reduction in the charging capacity of the battery module.

[0021] In some embodiments, a battery management module manages battery charging of a battery pack, the battery pack comprising a first battery module, a second battery module, and at least one switch. A first switch configuration of the at least one switch couples the first battery module and the second battery module in parallel, and a second switch configuration of the at least one switch couples the first battery module and the second battery module in series. The battery management module receives capability information from a battery charging system coupled to the battery pack. The battery management module determines whether the battery charging system is capable of fast charging based on the capability information. The battery management module applies the second switch configuration to the at least one switch to perform fast charging in response to determining that the battery charging system is capable of fast charging. In some embodiments, the capability information includes a maximum charging current, a maximum charging voltage, or both.

[0022] In some embodiments, a battery management module manages battery charging of the battery pack. The battery management module receives charging system capability information from the charging system. The battery management module retrieves local charging information about the battery pack. The battery management module determines a switch configuration of at least one switch based at least in part on the charging system capability information and the local charging information to connect the first and second battery modules either in series or in parallel. The battery management module applies the switch configuration to the at least one switch. For example, in some embodiments, the battery pack is part of an electric vehicle, and the local charging information includes the location of the electric vehicle. In another example, in some embodiments, receiving the local charging information includes receiving user input indicating a desired charging mode. In some embodiments, the charging system capability information includes a maximum charging voltage that the charging system can apply for charging. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] According to one or more various embodiments, the present disclosure is described in detail with reference to the following drawings. The drawings are provided for illustrative purposes only and depict only typical or example embodiments. These drawings are provided to facilitate understanding of the concepts disclosed herein and should not be considered as limitations on the breadth, scope or applicability of these concepts. It should be noted that for clarity and ease of illustration, these drawings are not necessarily drawn to scale.

[0024] Figure 1 shows a system diagram of an illustrative battery charger and an illustrative electric vehicle according to some embodiments of the present disclosure;

[0025] Figure 2 A system diagram showing an illustrative arrangement of battery modules, electrical components, and subsystems according to some embodiments of the present disclosure;

[0026] Figure 3 shows a system diagram of illustrative control circuitry, electrical components, and sensors according to some embodiments of the present disclosure;

[0027] Figure 4 a system diagram showing an illustrative arrangement of battery modules, electrical components, and subsystems during fast charging according to some embodiments of the present disclosure;

[0028] Figure 5 a system diagram showing an illustrative arrangement of battery modules, electrical components, and subsystems during fast charging according to some embodiments of the present disclosure;

[0029] Figure 6 A system diagram showing an illustrative arrangement of battery modules, electrical components, and subsystems according to some embodiments of the present disclosure;

[0030] Figure 7a system diagram showing an illustrative arrangement of battery modules, electrical components, and subsystems during fast charging according to some embodiments of the present disclosure;

[0031] Figure 8 a system diagram showing an illustrative arrangement of battery modules, electrical components, and subsystems during fast charging according to some embodiments of the present disclosure;

[0032] Fig. 9 A system diagram showing an illustrative arrangement of battery modules, electrical components, and subsystems according to some embodiments of the present disclosure;

[0033] Fig.10 shows a system diagram of an illustrative battery management module for managing battery power and charging according to some embodiments of the present disclosure;

[0034] Fig.11 is a flow chart of an illustrative process for managing battery charging according to some embodiments of the present disclosure;

[0035] Fig.12 is a flow chart of an illustrative process for managing faults according to some embodiments of the present disclosure;

[0036] Fig.13 is a flow chart of an illustrative process for managing battery charging based on battery charger capability information according to some embodiments of the present disclosure;

[0037] Fig.14 is a flow chart of an illustrative process for managing battery charging based in part on local charging information according to some embodiments of the present disclosure; and

[0038] Fig.15 is a flow chart of an illustrative process for managing battery charging according to some embodiments of the present disclosure. DETAILED DESCRIPTION

[0039] A configurable battery system according to the present disclosure, including, for example, an electric vehicle (EV) battery, can be arranged in such a manner that at least two battery modules are wired in parallel to achieve a target maximum voltage for an electrical load (e.g., 450V). For example, for DC fast charging, the electrical connections to these battery modules can be reconfigured so that the battery modules are wired in series to achieve a high voltage twice the target maximum voltage (e.g., 900V for a 450V target maximum voltage). Fast charging (e.g., high voltage charging) can allow two battery modules to be charged at a charging inlet at a charging current close to a desired current (e.g., a fixed maximum value). The charging inlet can include any hardware included in a battery charger, a connection between the battery charger and a battery pack, and any hardware for conducting the charging current in the battery pack that can carry current during charging. Compared to low voltage charging (e.g., battery modules wired in parallel) with the same total maximum current limit, the charging current for each battery module will nominally be halved compared to fast charging.

[0040] In some embodiments, a configurable battery system allows the technology of the present disclosure to be applied to electric vehicles to more fully utilize the potential of battery chargers. In some embodiments, it is desired to achieve specific charging targets. For example, a charging target of 150kW at 450V may require a current of 334A. In this illustrative example, it may be necessary to source components to continuously handle currents up to 400A for charging. These components may be difficult to source, expensive, heavy, or difficult to operate. As mentioned above, the target of SAE J1772 is 900V, 400A to achieve the maximum output of a typical DC fast charger. If the battery system can take advantage of charging at 900V, a charging target of 150kW can be achieved with only 167A, which can allow for more, better quality, or cheaper options for charging components. For example, a current of 167A may allow the use of different hardware than if the current is closer to 400A. In some embodiments, the limit of the charging rate may be the current that the battery module can accept.

[0041] In some embodiments, the configurable battery system of the present disclosure reduces or eliminates charging inlet hardware that is a major limitation on charging rate and a bottleneck for the battery module. For example, as battery chemistry improves and the battery cells of the batteries (e.g., of the battery module) are able to accommodate higher currents, the configurable battery system of the present disclosure may be able to supply the necessary power at higher currents. Reducing the charging current in a DC fast charging circuit (e.g., when modules are connected in series as opposed to in parallel) may also reduce or eliminate the need for cooling the charging hardware, as well as reduce the size required for DC fast charging cables. For example, in some cases, if the battery modules are charged in parallel, it may be required to use a 95mm cross-section.2 and 120mm 2 Such cables can be very large, heavy, rigid, and difficult to package. Also, if the components are at a higher voltage, such as, for example, at 900V (e.g., for electric vehicles), then the battery modules of the battery pack may be configured to charge and operate at 900V for all conditions.

[0042] In view of the foregoing, in some embodiments, it is desirable to achieve faster charging at a higher voltage (e.g., 900V for electric vehicles). One solution to achieve this may be to design the battery load to operate similarly at a higher voltage. If the off-the-shelf components cannot operate at a higher voltage, then custom components may need to be designed. This can be time-consuming and expensive. The configurable battery system of the present disclosure provides an improved and simpler solution that can maximize the DC fast charging rate. This configurable battery system provides a competitive charging rate while still enabling the use of off-the-shelf components. For example, when using a 450V charging source or a 900V charging source, the configurable battery of the present disclosure allows commercially available 450V components to be used for electric vehicles (e.g., air conditioning (AC) compressors, positive temperature coefficient (PTC) heaters, drive units, DC-DC converters, and onboard chargers (OBC)). In addition, in some embodiments, when the market can support it with price-competitive components, the configurable battery system of the present disclosure can seamlessly transition to a 900V architecture.

[0043] Figure 1 A system diagram of a charging arrangement 100 according to some embodiments of the present disclosure is shown, the charging arrangement 100 including an illustrative battery charger 110 and an illustrative electric vehicle 120. The electric vehicle 120 includes a battery pack 122, which may include one or more battery modules, and an electric vehicle subsystem 130. The electric vehicle subsystem 130 includes, for example, a rear drive unit 132, a front drive unit 134, an AC compressor 136, a battery management module 138, an HVAC PTC 140, an energy storage system 142, a DC-DC converter 144, an onboard charger (OBC) 146, an auxiliary system 148, and any suitable corresponding equipment.

[0044] In some embodiments, the battery management module 138 and the onboard charger 146 can be combined. For example, the battery management module 138 can be included in the onboard charger 146. In some embodiments, the battery management module 138 and the onboard charger 146 can be implemented in part or in whole as separate systems that can communicate with each other. For example, the onboard charger 146 can include a connector for interfacing with the battery charger, and the battery management module 138 can connect the charging terminals from the onboard charger 146 to the battery pack 122 via one or more controllable switches. In another example, the battery management module 138 can include a software package implemented on the processing equipment of the onboard charger 146, and the onboard charger can include charging hardware (e.g., connections, switches, and sensors).

[0045] In some embodiments, the battery management module 138 may be configured to manage the charging of the battery pack 122, which may include measuring one or more battery characteristics of the battery pack 122, changing the configuration of one or more switches, identifying whether a fault has occurred, providing power to one or more of the electric vehicle subsystems 130 (e.g., the rear drive unit 132), communicating with the battery charger 110, any other suitable action, or any combination thereof. The battery management module 138 may be coupled to the battery pack 122 via the coupling 154. Thus, the battery management module 138 may include, for example, electrical components (e.g., switches, bus bars, resistors, capacitors), control circuitry (e.g., for controlling suitable electrical components), and measurement equipment (e.g., for measuring voltage, current, impedance, frequency, temperature, or other parameters).

[0046] In some embodiments, the electric vehicle 120 can be plugged into or otherwise connected to the battery charger 110 via couplings 150 and 152. For example, the battery charger 110 can be coupled to the electric vehicle 120 using a single cable having more than one appropriately sized conductor (e.g., with an SAE J1772 charging plug). The single cable can include conductors for carrying charging current (e.g., coupling 150) and conductors for transmitting information (e.g., coupling 152). It will be understood that any suitable lead arrangement can be used in accordance with the present disclosure. For example, in some embodiments, coupling 152 can include both charging leads and information leads, and the arrangement 100 need not include coupling 150.

[0047] The battery charger 110 may be coupled to a power transmission grid as a power source, and may be configured to provide a charging current to a battery pack 122 of an electric vehicle 120 at a suitable charging voltage. In some embodiments, the battery charger 110 may be capable of charging a battery pack (e.g., battery pack 122) at one or more voltages under one or more current limits. For example, according to SAE J1772, the battery charger 110 may be configured to provide 400A at 900V for charging. In another example, the battery charger 110 may receive information from the electric vehicle subsystem 130 (e.g., from the onboard charger 146 via the coupling 152) that describes what voltage, current, or both the electric vehicle 120 can be charged with. For illustration, the battery charger 110 may be capable of charging the electric vehicle 120 at either 450V (e.g., slow charging) or 900V (e.g., fast charging), and may provide one of these voltages based on communication with the electric vehicle 120. The battery charger 110 may provide a charging current limited by one or more constraints. For example, the electric vehicle 120 may communicate to the battery charger 110 what charging current is desired for charging. In another example, based on insulation and heat transfer considerations, a cable type (eg, coupling 150) may have a maximum associated current capacity.

[0048] In some embodiments, the electric vehicle subsystem 130 can be configured to operate at one or more load voltages. For example, the battery management module 138 can manage the power supply to other subsystems of the electric vehicle subsystem 130 at 450V. In another example, the DC-DC converter 144 can provide 12V (e.g., converted from the voltage of the battery pack 122) to one or more components of the electric vehicle 120.

[0049] In some embodiments, the battery pack 122 includes two or more battery modules, each battery module having an associated voltage. The battery pack 122 may include a busbar (e.g., a terminal for connecting a battery module, a pre-charging circuit, or a measuring device), a switch (e.g., a contactor for opening and closing a battery connection), a sensor (e.g., for sensing temperature, voltage, current, impedance, or other parameters), any other suitable component, or any suitable combination thereof.

[0050] While in the charging configuration, at least some of the electric vehicle subsystems 130 may be operating or otherwise drawing power (i.e., being device loads). The battery management module 138 may be configured to manage the provision of power to the subsystems of the electric vehicle system 130 while the battery charger 110 is connected (e.g., via couplings 150 and 152) and providing a charging current at an appropriate voltage. Thus, the battery management module 138 may be configured to provide power to the subsystems during low voltage charging (e.g., slow charging) or high voltage charging (e.g., fast charging).

[0051] The battery management module can be implemented in hardware, software or a combination thereof. The battery management module can be an independent module, a module distributed in a processing device, a module integrated into an existing electric vehicle system, or a combination thereof.

[0052] Figure 2 A system diagram of an illustrative arrangement 200 of battery modules 210 and 211, electrical components, and subsystems according to some embodiments of the present disclosure is shown. Each of the battery modules 210 and 211 includes a positive terminal and a negative terminal. For example, the battery module 210 has a positive terminal connected to the bus 234 and a negative terminal connected to the bus 230. In addition, the battery module 211 has a positive terminal connected to the bus 232 and a negative terminal connected to the switch 250.

[0053] like Figure 2 As shown in , switches 250, 252, 254, and 256 are single-pole double-throw (SPDT). For example, any or all of switches 250, 252, 254, and 256 can be the "ON-ON" or "ON-OFF-ON" type of SPDT switch. Any or all of switches 250, 252, 254, and 256 can include at least one contactor, a relay (e.g., solid-state or other form), a transistor (e.g., an insulated gate bipolar transistor (IGBT)), any other suitable device for switching a pole between two "on" positions, or any combination thereof. For example, switches 250, 252, 254, and 256 can all be SPDT contactors. In another example, switches 250, 252, 254, and 256 can each include two single-pole single-throw (SPST) contactors appropriately wired to achieve SPDT connectivity. As Figure 2 As shown in FIG, switches 260 and 262 are both SPST switches configured to connect and disconnect corresponding terminals of the battery charger 270 to and from the bus bars 230 and 232. Either or both of the switches 260 and 262 may include a contactor, a relay (e.g., solid state or otherwise), a transistor (e.g., an insulated gate bipolar transistor (IGBT)), any other suitable device for switching a pole between an “off” and “on” position, or any combination thereof.

[0054] like Figure 2 As shown in FIG. 1 , battery modules 210 and 211 are connected in series. For example, switches 250 and 252 are configured to connect the positive terminal of battery module 210 to the negative terminal of battery module 211. Figure 1 One or more vehicle loads 280 of the electric vehicle subsystem 130 are shown connected to the battery module 210 via switches 256 and 254. Figure 2 As shown in , switch 256 connects bus 230 to the negative terminal of vehicle load 280 , while switch 254 connects bus 234 to the positive terminal of vehicle load 280 .

[0055] In some embodiments, battery module 210 may include submodules 202, 204, 206, and 208, which may also be referred to as battery cells. Similarly, in some embodiments, battery module 211 may also include submodules 203, 205, 207, and 209, which may also be referred to as battery cells. For example, battery module 210 may be referred to as a "string of battery cells" (i.e., battery cells connected in series). The voltage of battery module 210 may be a combination of battery cells 202, 204, 206, and 208. For example, Figure 2 As illustratively shown in FIG. 2 , the voltage of battery module 210 is the sum of the voltages of each of battery cells 202, 204, 206, and 208. In another example, a battery module (e.g., battery module 210 or battery module 211) may include one or more battery cells connected in parallel (e.g., to increase the current capacity of the battery module). For clarity, the present disclosure is described in terms of battery modules.

[0056] For simplicity, arrangement 200 illustrates two battery modules, but more than two battery modules may be managed in accordance with the present disclosure. For example, three battery modules each operating at 300 V may be connected using a switch configuration in parallel (e.g., charging at 300 V) or in series (e.g., charging at 900 V). In another example, three battery modules each operating at 450 V may be configured in parallel (e.g., charging at 450 V), or two of the three may be configured in parallel and then connected in series with the third (e.g., charging at 900 V). In accordance with the present disclosure, any suitable number of battery modules may be managed (e.g., connected in series or in parallel with a switch configuration). It will be understood that a battery module may include one or more submodules (e.g., separate submodules that may be coupled together to form a module).

[0057] Figure 3A system diagram of illustrative control circuitry 310, electrical components, and sensors 350 according to some embodiments of the present disclosure is shown. In some embodiments, battery management module 302 may include control circuitry 310 and sensor 350. Battery management module 302 may be used, for example, to control Figure 2 In some embodiments, the battery management module 302 or its control circuit system 310 may be incorporated into Figure 2 Arrangement 200 or Figure 1 In some embodiments, the battery management module 302 may include switches 250, 252, 254, 256, 260, and 262. As illustratively shown in the arrangement 300, the control circuit system 310 may be configured to control the switches 250, 252, 254, 256, 260, and 262. For example, the control circuit system 310 may place one or both of the switches 260 and 262 in an off position or an on position. In another example, the control circuit system 310 may place any one of the switches 250, 252, 254, and 256 in one of two on positions or an off position.

[0058] The control circuit system 310 may include a processor, a power supply, a power management component (e.g., a relay, a filter, a voltage regulator), an input / output IO (e.g., GPIO, analog, digital), a memory, a communication equipment (e.g., CANbus hardware, Modbus hardware, or a WiFi module), any other suitable component, or any combination thereof. In some embodiments, the control circuit system 310 may include one or more microprocessors, microcontrollers, digital signal processors, programmable logic devices, field programmable gate arrays (FPGAs), application specific integrated circuits (ASICs), etc., and may include a multi-core processor. In some embodiments, the control circuit system 310 may be distributed across multiple separate processors or processing units (e.g., multiple processing units of the same type or multiple different processors).

[0059] In some embodiments, the control circuit system 310 executes instructions for the battery management module stored in the memory. The memory can be an electronic storage device that is part of the control circuit system 310. For example, the memory can be configured to store electronic data, computer software, or firmware, and can include random access memory, read-only memory, a hard drive, an optical drive, a solid-state device, or any other suitable fixed or removable storage device, and / or any combination thereof. Non-volatile memory can also be used (e.g., to start boot routines and other instructions).

[0060] The control circuit system 310 can be coupled to the switches 250, 252, 254, 256, 260, and 262 using any suitable wired or non-wired coupling. For example, the control circuit system 310 can be coupled to the switches 250, 252, 254, 256, 260, and 262 using a suitable cable with any suitable termination (e.g., a plug, a screw-on terminal, a soldered connection). In another example, the control circuit system 310 can communicate wirelessly (e.g., using WiFi or Bluetooth) with the switches 250, 252, 254, 256, 260, and 262, each of which can include a transceiver to receive the communication and actuate the corresponding switch (e.g., which can also include a power source).

[0061] In some embodiments, the battery management module may process signals from one or more of the sensors 350, which may, but need not, be included in the battery management module 302. The sensors 350 may include sensors for sensing voltage, current, impedance, temperature, any other suitable parameter, or any combination of parameters. For example, the sensors 350 may include a respective voltage sensor for each of the battery modules 210 and 211 measured across appropriate terminals. In another example, the sensor 350 may include a temperature sensor coupled to the battery module 210 (e.g., to determine whether the battery module 210 is overheated). In some embodiments, the sensor 350 may be included in any one or all of the switches 250, 252, 254, 256, 260, and 262. For example, the switch 250 may be a SPDT relay, and the sensor 350 may include additional switch terminals for determining the position of the switch 250 (e.g., using a lower voltage / power circuit).

[0062] Figure 4-6 A system diagram of corresponding illustrative arrangements 400, 500, and 600 of battery modules 210 and 211, electrical components, and subsystems according to some embodiments of the present disclosure is shown. The arrangements 400, 500, and 600 differ in the corresponding switch configurations of switches 250, 252, 254, and 256. Figure 4-6 As shown in , switches 260 and 262 are in a closed (ie, on) position (eg, charging configuration). For example, each of battery module 210 and battery module 211 may nominally operate at 450 V. In another example, battery charger 270 may be configured to charge at least at both 450 V and 900 V.

[0063] Arrangement 400 includes battery modules 210 and 211 connected in series through a configuration of switches 250 and 252. Arrangement 400 also includes terminals of a vehicle load 280 (e.g., at busbars 230 and 234) connected to corresponding terminals of battery module 210. Thus, in arrangement 400, vehicle load 280 is not connected to battery module 211.

[0064] Arrangement 500 includes battery modules 210 and 211 connected in series through a configuration of switches 250 and 252. Arrangement 500 also includes terminals of vehicle load 280 (e.g., at busbars 234 and 232) connected to corresponding terminals of battery module 211. Thus, in arrangement 500, vehicle load 280 is not connected to battery module 210.

[0065] Arrangement 600 includes battery modules 210 and 211 connected in parallel through a configuration of switches 250 and 252. Arrangement 600 also includes terminals of a vehicle load 280 connected to corresponding terminals of battery modules 210 and 211 (e.g., at busbars 230 and 232). In this arrangement, vehicle load 280 is also connected in parallel to corresponding terminals of battery charger 270.

[0066] refer to Figure 4-6 In the arrangements 400, 500 and 600, switches 250, 252, 254 and 256 can be used to accommodate two different charging settings of the battery charger 270, and to apply the vehicle load to either or both of the battery modules 210 and 211. In addition, switches 260 and 262 can be used to connect and disconnect the battery charger 270 to the bus bars 232 and 230, respectively.

[0067] In a first scenario (e.g., a fast charge configuration, or a high voltage configuration), the battery charger 270 may be configured to charge at 900V, and the battery module 210, the battery module 211, and the vehicle load 280 may be configured to operate at 450V (e.g., nominally half of 900V). Thus, the battery charger 270 should not be directly connected to the vehicle load 280, nor should it be directly connected to either of the battery modules 210 or 211. In this scenario, the switches 250 and 252 may be placed in a first configuration, as shown in arrangements 400 and 500, to connect the battery modules 210 and 211 in series. Thus, the total voltage between the busbars 230 and 232 may then be nominally 900V, thereby allowing connection to the battery charger 270. In the first scenario, the switches 254 and 256 may be configured to connect the vehicle load 280 across either the battery module 210 or the battery module 211, but not across both. Arrangements 400 and 500 illustrate two different setups for the first case.

[0068] In a second scenario (e.g., a slow charging configuration, or a low voltage configuration), the battery charger 270 can be configured to charge at 450V, and the battery modules 210, 211, and the vehicle load 280 can also be configured to operate at 450V (e.g., the same as the charging voltage of the battery charger 270). Thus, the battery charger 270 can be directly connected to the vehicle load 280 and directly connected to either or both of the battery modules 210 or 211. In the second scenario, the switches 250 and 252 can be placed in a second configuration, such as Figure 6 600 to connect battery modules 210 and 211 in parallel. Thus, the total voltage between busbars 230 and 232 can then be nominally 450V, allowing connection to battery charger 270. In a second scenario, switches 254 and 256 can be configured to connect vehicle load 280 across both battery modules 210 and 211 and thus also in parallel with battery charger 270. Arrangement 600 illustrates the second scenario.

[0069] Referring to arrangements 400, 500, and 600, the battery management module may include control circuitry for configuring switches 250, 252, 254, 256, 260, and 262. For example, if fast charging is desired and battery module 210 has a slightly greater voltage than battery module 211, the battery management module may configure switches 250, 252, 254, 256, 260, and 262 to implement arrangement 400 so as to balance the charging of the two battery modules. In another example, if slow charging is desired and both battery module 210 and battery module 211 are functional, the battery management module may configure switches 250, 252, 254, 256, 260, and 262 to implement arrangement 600.

[0070] Figure 7-9 A system diagram of corresponding illustrative arrangements 700, 800, and 900 of battery modules 710 and 711, electrical components, and subsystems according to some embodiments of the present disclosure is shown. The arrangements 700, 800, and 900 differ in the corresponding switch configurations of switches 750, 752, 754, 755, 756, and 757. Figure 7-9 As shown in , switches 760 and 762 are maintained in a closed (ie, on) position (e.g., charging configuration). For example, each of battery module 710 and battery module 711 can nominally operate at 450V. In another example, battery charger 770 can be configured to charge at least at both 450V and 900V.

[0071] Arrangement 700 includes battery modules 710 and 711 connected in series through a configuration of switches 750, 752, 754, 755, 756, and 757. Arrangement 700 also includes terminals of a vehicle load 780 (e.g., at busbars 730 and 734) connected to corresponding terminals of battery module 710. Thus, in arrangement 700, vehicle load 780 is not connected to battery module 711.

[0072] Arrangement 800 includes battery modules 710 and 711 connected in series through a configuration of switches 750, 752, 754, 755, 756, and 757. Arrangement 800 also includes terminals of a vehicle load 780 (e.g., at busbars 734 and 732) connected to corresponding terminals of battery module 711. Thus, in arrangement 800, vehicle load 780 is not connected to battery module 710.

[0073] Arrangement 900 includes battery modules 710 and 711 connected in parallel through a configuration of switches 750, 752, 754, 755, 756, and 757. Arrangement 900 also includes terminals of a vehicle load 780 (e.g., at busbars 730 and 732) connected to corresponding terminals of both battery modules 710 and 711. In this arrangement, vehicle load 780 is also connected to corresponding terminals of battery charger 770.

[0074] refer to Figure 7-9 In the arrangements 700, 800, and 900, switches 750, 752, 754, 755, 756, and 757 may be used to accommodate two different charging settings (e.g., fast charging or slow charging) of battery charger 770, as well as applying a vehicle load to either or both of battery modules 710 and 711 (e.g., Figure 7-8 ). In addition, switches 760 and 762 may be used to connect and disconnect a battery charger 770 from bus bars 732 and 730, respectively.

[0075] In a first scenario (e.g., a fast charge configuration, or a high voltage configuration), the battery charger 770 may be configured to charge at 900V, and the battery module 710, the battery module 711, and the vehicle load 780 may be configured to operate at 450V (e.g., nominally half of 900V). Thus, the battery charger 770 should not be directly connected to the vehicle load 780, nor should it be directly connected to either of the battery modules 710 or 711. In this scenario, the switches 750 and 752 may be placed in a first configuration, as shown in arrangements 700 and 800, to connect the battery modules 710 and 711 in series. Thus, the total voltage between the busbars 730 and 732 may then be nominally 900V, thereby allowing connection to the battery charger 770. In the first scenario, the switches 754, 755, 756, and 757 may be configured to connect the vehicle load 780 across either the battery module 710 or the battery module 711, but not across both. Arrangements 700 and 800 illustrate the first case.

[0076] In a second scenario (e.g., a slow charging configuration, or a low voltage configuration), the battery charger 770 can be configured to charge at 450V, and the battery modules 710, 711, and the vehicle load 780 can also be configured to operate at 450V (e.g., the same as the charging voltage of the battery charger 770). Thus, the battery charger 770 can be directly connected to the vehicle load 780, and directly connected to either or both of the battery modules 710 or 711. In the second scenario, the switches 750 and 752 can be placed in a second configuration, as shown in the arrangement 900, to connect the battery modules 710 and 711 in parallel. Thus, the total voltage between the busbars 730 and 732 can then be nominally 450V, thereby allowing connection to the battery charger 770. In the second scenario, the switches 754, 755, 756, and 757 can be configured to connect the vehicle load 780 across both the battery modules 710 and 711. Arrangement 900 illustrates the second scenario.

[0077] With reference to arrangements 700, 800, and 900, the battery management module may include control circuitry for configuring switches 750, 752, 754, 755, 756, 757, 760, and 762. For example, if fast charging is desired and battery module 710 has a slightly greater voltage than battery module 711, the battery management module may configure switches 750, 752, 754, 755, 756, 757, 760, and 762 to implement arrangement 700 so as to balance the charging of the two battery modules. In another example, if slow charging is desired and both battery module 710 and battery module 711 are functional, the battery management module may configure switches 750, 752, 754, 755, 756, 757, 760, and 762 to implement arrangement 900.

[0078] Fig.10 A system diagram of an illustrative arrangement 1000 is shown according to some embodiments of the present disclosure, the arrangement 1000 including a battery management module 1050 for managing battery power and charging. The arrangement 1000 may show, for example, an arrangement in which the battery modules 1010 and 1020 each have a positive terminal and a negative terminal, all of which are coupled to the battery management module 1050. The battery management module 1050 may include any suitable control circuitry to control, start, stop, limit, characterize (e.g., measure), check, or otherwise manage the charging of the battery modules 1010 and 1020. In the illustrative example, the arrangement 1000 may be applied to Figure 4-9 In addition, arrangement 1050 may be implemented as Figure 1-9 part of any system.

[0079] The battery management module 1050 may include a pre-charging system 1052, a safety system 1054, a fault checking system 1056, an electrical connection 1058, an electrical component 1060, any other suitable system or component, or any combination thereof. For example, the battery management module 1050 may include a bus bar, a junction box, a fuse, a switch (e.g., a relay or contactor), a circuit breaker, an electrical filter (e.g., to reduce noise), a capacitor (e.g., for pre-charging), a resistor (e.g., for pre-charging), a diode, an inductor (e.g., a choke), processing equipment, measurement equipment (e.g., a current sensor, a voltage sensor), IO hardware (e.g., an RJ45 jack and an Ethernet controller), and memory. In some embodiments (e.g., such as Fig.10), the battery management module 1050 can be coupled to a battery charger 1070 (e.g., to receive a charge), and to a vehicle load 1080 (e.g., including any other subsystems of the electric vehicle subsystem 130). Thus, the battery management module 1050 can manage the interaction of the battery modules 1010 and 1020 with the battery charger 1070 and the vehicle load 1080.

[0080] The pre-charge system 1052 may include circuitry for reducing the potential difference (ie, voltage difference) across the connections of the switch (eg, to reduce inrush current). For example, the pre-charge system 1052 may include capacitors and resistors to control the current and voltage across the switch terminals.

[0081] The safety system 1054 may include, for example, circuitry for monitoring a proximity pilot signal (e.g., to identify a connector status), circuitry for measuring parameters (e.g., voltage, current, temperature, resistance), circuitry for communicating with any electric vehicle subsystem 130, any other suitable circuitry, or any combination thereof. In some embodiments, the battery management module 1050 may use the safety system 1054 to determine a switch configuration to use. For example, if the safety system 1054 determines that an unsafe condition is occurring, the battery management module may determine a switch configuration that isolates or otherwise disconnects one or more of the battery charger 1070, the vehicle load 1080, and the battery modules 1010 and 1020.

[0082] The fault checking system 1056 may include, for example, circuitry for measuring parameters (e.g., voltage across the battery module, charging current, battery module temperature, resistance across appropriate terminals), circuitry for communicating with the onboard charger 146, any other suitable circuitry, or any combination thereof. In some embodiments, the fault checking system 1056 may be included in the safety system 1054. In some embodiments, the safety system 1054 may be included in the fault checking system 1056. In some embodiments, the battery management module may determine that a fault has occurred based on the fault checking system 1056.

[0083] Connection 1058 may include, for example, a bus bar, a branch point, a connector, a terminal, any other suitable component for connecting a charging conductor, or any combination thereof. For example, connection 1058 may include a high voltage DC connector, a crimped cable connection, a welded or brazed connection, a screw-on terminal, a spring-loaded terminal, a ground terminal, any other suitable connection, or any combination thereof.

[0084] Component 1060 may include, for example, filters, resistors, capacitors, inductors, diodes, amplifiers, contactors, relays, any other suitable components for managing the charging of one or more battery modules. In an illustrative example, the combination of connection 1058 and component 1060 may be a control circuit system for applying a switch configuration to one or more switches.

[0085] In some embodiments, for example, the battery management module 1050 may include a control circuit system (e.g., Figure 3 control circuit system 310) and sensors (e.g., Figure 3 In some embodiments, the battery management module 1050 may be an onboard charger (e.g., Figure 1 part of or in combination with an onboard charger 146).

[0086] The battery management module can manage the operation and charging of a battery pack having two or more battery modules. To balance utilization and take advantage of fast charging when desired, the battery management module can determine and apply a switch configuration to manage charging. For example, the battery management module can manage the provision of power to an electrical load during low voltage charging by managing which battery module provides power. In another example, the battery management module can manage switching electrical loads between battery modules to balance utilization. Fig.11 is a flow chart of an illustrative process 1100 for managing the charging of a battery pack according to some embodiments of the present disclosure. It should be noted that the process 1100 or any of its steps may be Figure 1-10 1100. In addition, one or more steps of process 1100 may be incorporated into or combined with one or more steps of any other process or embodiment described herein. In some embodiments, process 1100 may include a battery management module managing the charging of a first battery module and a second battery module coupled in series. In some embodiments, the battery management module may be coupled to a battery charger, which may provide a charging current to the battery management module at a charging voltage. In some embodiments, charging the first battery module and the second battery module while connected in series may correspond to fast charging.

[0087] Step 1104 may include a battery management module that uses at least one switch in a first switch configuration to couple the electrical load in parallel to the first battery module during charging. In some embodiments, the at least one switch may include a plurality of switches configured to couple the electrical load in parallel to the first battery module during charging. For example, referring to Figure 2In the arrangement 200, switches 256 and 254 are in a configuration that couples a vehicle load 280 (eg, an electrical load) to a battery module 210 (eg, a first module). In another example, referring to Figure 8 In arrangement 800 , switches 754 , 755 , 756 , and 757 are in a configuration that couples a vehicle load 780 (eg, an electrical load) to a battery module 711 (eg, a first module).

[0088] Step 1106 may include the battery management module determining a first battery characteristic of the first battery module during charging. In some embodiments, the first battery characteristic may be a numerical value, such as, for example, a measurement result (e.g., a voltage across the first battery module), a duration, a charging start time, or other suitable value. In some embodiments, the first battery characteristic may be a state (e.g., a state identifier), such as, for example, "fully charged", "voltage high", "voltage low", or other suitable state. In another example, the battery management module may determine the time elapsed since the last charge, the time elapsed since the last load, the total number of charges, the cumulative charging time, any other suitable metric associated with historical charging behavior, or any combination thereof.

[0089] Step 1108 may include the battery management module determining a second battery characteristic of the second battery module during charging. In some embodiments, the second battery characteristic may be a numerical value, such as, for example, a measurement result (e.g., a voltage across the first battery module), a duration, a charging start time, or other suitable value. In some embodiments, the second battery characteristic may be a state (e.g., a state identifier), such as, for example, "fully charged", "high voltage", "low voltage", "time to charge", or other suitable states. In another example, the battery management module may determine the time elapsed since the last charge, the time elapsed since the last load, the total number of charges, the cumulative charging time, any other suitable metric associated with historical charging behavior, or any combination thereof.

[0090] It will be understood that steps 1106 and 1108 may be combined in any suitable manner. In some embodiments, the battery management module may determine a differential battery characteristic based on a comparison of two battery modules. For example, the battery management module may determine the difference between the voltage across the first battery module and the voltage across the second battery module. To illustrate, if the voltage across the first battery module is 440V and the voltage across the second battery module is 452V, then the battery management module may determine a voltage difference of 12V or -12V depending on how the difference is determined. In some embodiments, the battery management module may determine the second battery characteristic based at least in part on the first battery characteristic. For example, the battery management module may determine that the first battery characteristic is 452V (e.g., the voltage across the first battery module is 452V). The battery management module may then determine that the second battery characteristic is -6V (e.g., the voltage across the second battery module is 446V, or 6V less than the first battery module).

[0091] Step 1110 may include the battery management module determining to apply a second switch configuration to at least one switch based on the first battery characteristic and the second battery characteristic, wherein the second switch configuration couples the electrical load in parallel to the second battery module during charging. In some embodiments, the battery management module may select from a set of switch configurations. For example, a set of predetermined switch configurations may be selected, each predetermined switch configuration describing one or more switch positions to be used in a particular situation. In some embodiments, the battery management module may determine to apply a switch configuration based on a subset of one or more switches. For example, the battery module may determine to apply a switch configuration based on a subset of one or more switches. For example, the battery module may determine to apply a switch configuration based on a subset of one or more switches. Figure 4-6 switches 254 and 256), charging switch configuration (e.g., for Figure 4-6 switches 260 and 262) and mode switch configurations (e.g., Figure 4-6 switches 250 and 252) to determine the application switch configuration.

[0092] Step 1112 may include the battery management module applying the second switch configuration (e.g., of step 1110) to at least one switch. In some embodiments, step 1112 may include the battery management module sending one or more signals to one or more corresponding switches to change the switch position. For example, the battery management module may send a transistor-transistor level (TTL) signal to a relay or contactor to change the position. In another example, the battery management module may send a DC signal (e.g., 5V, 12V, 24V, or other voltage) to one or more relays or contactors to change the position. In another example, the battery management module may send an AC signal (e.g., 110VAC, 24VAC, or other voltage) to one or more relays or contactors to change the position. In another example, the battery management module may send a command to a relay or contactor (e.g., which may include a control circuit system) via a CANbus to change the position. In some embodiments, step 1112 may include the battery management module not changing one or more switches. For example, when changing the coupling of the electrical load from the first battery module to the second battery module, one or more switches may remain in one position.

[0093] expected Fig.11 The steps or descriptions of can be used with any other embodiment of the present disclosure. Fig.11 The steps and descriptions described may be performed in an alternative order or in parallel to further achieve the objectives of the present disclosure. For example, battery characteristics may also be determined and used to determine the switch configuration used in step 1104. As another example, each of these steps may be performed in any order or in parallel or substantially simultaneously to reduce lag or increase the speed of the system or method. Any of these steps may also be skipped or omitted from the process. In addition, it should be noted that with respect to Figure 1-10 Any of the devices or equipment discussed may be used alone or in combination to perform Fig.11 One or more steps in .

[0094] The battery management module can manage the occurrence of a fault in a battery pack having two or more battery modules. To prevent damage or an unsafe condition, the battery management module can determine that a fault has occurred and, in view of the fault, apply a switch configuration to manage operation, charging, or both. For example, the battery management module can disconnect the battery module from the electrical load to prevent the operating voltage from deviating from an acceptable range (e.g., an electrical short circuit can cause the voltage to drop below a threshold). Fig.12 is a flow chart of an illustrative process 1200 for managing failures according to some embodiments of the present disclosure. It should be noted that the process 1200 or any of its steps may be Figure 1-10In addition, one or more steps of process 1200 may be incorporated into or combined with one or more steps of any other process or embodiment described herein.

[0095] refer to Figure 6 , for example, the battery module 211 may have a fault, such as a short circuit. As a result, the voltage across the battery module 211 may drop, which may damage or otherwise render the vehicle load 280 unusable. The battery management module may open (e.g., set to the OFF position) switches 250, 252, 260, and 262, and position switch 256 to connect the bus 230 to the vehicle load 280, and position switch 254 to connect the bus 234 to the vehicle load 280. This switch configuration isolates the battery module 211 and allows the vehicle load 280 to be powered by the battery module 210 at the same operating voltage, albeit with a smaller current capacity (e.g., without the battery module 211 connected in parallel). Reference Figure 4 If the battery module 211 exhibits a fault in the arrangement 400, the battery management module may first apply a switch configuration to achieve Figure 6 Arrangement 600, and then perform the above switch configuration to isolate the battery module 211. In some embodiments, if the battery management module identifies a fault during slow charging, it can isolate the failed battery module while still powering the vehicle load. In some embodiments, if the battery management module identifies a fault during fast charging, it can shut down charging and disconnect the vehicle load. In some embodiments, if the battery management module identifies a fault during fast charging, it can switch to slow charging and isolate the failed battery module.

[0096] Step 1202 may include the battery management module identifying, using the control circuit system, a fault occurrence in a battery module of a plurality of battery modules when at least one switch is in a first switch configuration. In some cases, at least one switch in the first switch configuration couples the plurality of battery modules in parallel with each other and with an electrical load. A fault is an event or otherwise a change in state of a battery module, an associated component, or both, that negatively affects the operation or charging of the battery module. A fault occurrence refers to either the occurrence of the fault itself, or the time at which the battery management module identifies that the fault has occurred. In some embodiments, the battery management module may scan (e.g., periodically test or measure) corresponding battery characteristics of one or more battery modules to check for faults. In some embodiments, the battery management module may continuously monitor corresponding battery characteristics of one or more battery modules to check for faults.

[0097] In some embodiments, the battery management module can identify the occurrence of a fault at step 1202 based on at least one sensor configured to measure temperature (e.g., a thermocouple, a thermistor, or a resistance temperature detector). For example, the battery management module can include a thermocouple interface coupled to a thermocouple that can measure the battery module temperature. If the temperature increases (e.g., above a threshold), the battery management module can determine that a fault has occurred (e.g., an increased temperature can indicate a fault).

[0098] In some embodiments, the battery management module may identify the occurrence of a fault in step 1202 based on at least one sensor configured to measure voltage (e.g., a digital multimeter or a GPIO with a voltage divider circuit). For example, the battery management module may measure the battery module voltage. If the voltage is out of range, the battery management module may determine that a fault has occurred (e.g., a short circuit or an open circuit has occurred). In some embodiments, the battery management module may interrupt the current in the battery module to measure the open circuit voltage (e.g., for a short period of time so that it is not noticeable to the electrical load).

[0099] In some embodiments, the battery management module may identify the occurrence of a fault in step 1202 based on at least one sensor configured to measure current (e.g., a digital multimeter, a precision resistor, or a current shunt). For example, the battery management module may measure the charging current or the load current of the battery module. If the current is out of range, the battery management module may determine that a fault has occurred (e.g., a short circuit or an open circuit has occurred). In some embodiments, the battery management module may interrupt the circuit in the battery module to check that the current is zero (e.g., to check for a short circuit or an unexpected ground).

[0100] In some embodiments, the battery management module may identify the occurrence of a fault in step 1202 based on at least one sensor configured to measure impedance (e.g., a digital multimeter, a passive circuit component). For example, the battery management module may measure the impedance of the battery module by providing a signal modulation and measuring the voltage response. If the impedance is out of range, the battery management module may determine that a fault has occurred (e.g., a circuit has changed). In some embodiments, the battery management module may interrupt the circuit in the battery module to check the impedance of the battery module.

[0101] Step 1204 may include the battery management module determining a second switch configuration in response to identifying a fault occurrence in one of the battery modules. In some embodiments, the battery management module may determine a second switch configuration that isolates, disconnects, or otherwise mitigates the effect of the fault occurrence on battery charging. In some embodiments, the battery management module may stop charging (e.g., Figure 4-6In some embodiments, the battery management module can select from a set of switch configurations. For example, a switch configuration can be selected from a set of predetermined switch configurations, each switch configuration describing one or more switch positions to be applied when a fault is identified. In some embodiments, the battery management module can determine the switch configuration to apply based on a subset of one or more switches. For example, the battery module can select from a set of switch configurations. For example, the battery module can select from a set of predetermined switch configurations. For example, the battery management module can select from a set of predetermined switch configurations. Figure 4-6 switches 254 and 256), charging switch configuration (e.g., for Figure 4-6 switches 260 and 262) and mode switch configurations (e.g., Figure 4-6 switches 250 and 252) to determine the application switch configuration.

[0102] In some embodiments, the battery management module may periodically disconnect each battery module to measure the open circuit voltage across the battery modules. For example, the battery management module may disconnect each battery module for a predetermined period of time (e.g., 10 milliseconds, or any other suitable time sufficient to reach a near open circuit voltage and perform a measurement). If the battery management module identifies a low voltage (e.g., below a threshold), then the battery management module may identify that a fault has occurred in that battery module. The battery management module may accordingly disconnect the failed battery module from the load (e.g., to Figure 2 OFF position of switch 250), disconnecting the battery charger from the battery module (e.g., using Figure 4-6 260 and 262), disconnecting the electrical load from the battery module (e.g., using Figure 4-6 switches 254 and 256), or a combination thereof.

[0103] Step 1206 may include the battery management module applying a second switch configuration to at least one switch. In some cases, the at least one switch in the second switch configuration decouples the failed battery module from the electrical load and couples the remaining one or more battery modules of the plurality of battery modules that have not failed to the electrical load. Thus, the resulting arrangement may include an electrical load coupled to the remaining one or more battery modules (e.g., still capable of providing current at an operating voltage) and may be decoupled from the failed battery module by disconnecting one or both terminals of the failed battery module, any corresponding circuit system, or any combination thereof.

[0104] In the illustrative example, reference Figure 6600, Table 1 shows an illustrative switch configuration (i.e., battery modules 210 and 211 in parallel, connected to an electrical load). With switches 260 and 262 either open (e.g., not charging, or not connected to a battery charger, as shown in Table 1) or closed (e.g., charging), the battery management module may identify at step 1202 that the battery module 211 has failed. At step 1204, the battery management module may determine the switch configuration of Table 2 as the desired switch configuration when a fault is detected in the battery module 211 and when not charging (e.g., in response to the occurrence of a fault).

[0105] Table 1: Illustrative switch configuration before fault (e.g. Figure 6 )

[0106] Switch ID Configuration Switch 250 Connect 211(-) to 210(-) Switch 252 Connect 211(+) to 210(+) Switch 254 Connect 250 to 211 (+) Switch 256 Connect 250 to 210(-) Switch 260 Open Switch 262 Open

[0107] Table 2: Illustrative switch configuration after a fault.

[0108] Switch ID Configuration Switch 250 OFF position Switch 252 OFF position Switch 254 Connect 250 to 210 (+) Switch 256 Connect 250 to 210(-) Switch 260 Open Switch 262 Open

[0109] expected Fig.12 The steps or descriptions of can be used with any other embodiment of the present disclosure. Fig.12 The steps and descriptions described may be performed in alternative orders or in parallel to further achieve the objectives of the present disclosure. For example, each of these steps may be performed in any order or in parallel or substantially simultaneously to reduce the lag of the system or method or to increase the speed of the system or method. Any of these steps may also be skipped or omitted from the process. In addition, it should be noted that with respect to Figure 1-10 Any of the systems and corresponding components discussed may be used alone or in combination to perform Fig.12 One or more steps in .

[0110] The battery management module can manage the charging of the battery pack based on the capabilities or limitations of the battery charger. In order to utilize fast charging when desired or available, and to determine the appropriate switch configuration in view of the coupled battery charger, the battery management module can determine and apply the switch configuration to manage charging. For example, the battery management module, the onboard charger, or both can determine whether the battery charger can provide AC power, DC power, what voltage it can provide, what current limitations are there, charging time limits, or other battery charger capability information. Fig.13 is a flow chart of an illustrative process 1300 for managing charging of a battery pack based on battery charger capability information according to some embodiments of the present disclosure. It should be noted that the process 1300 or any of its steps may be performed in any manner. Figure 1-10In addition, one or more steps of process 1300 may be incorporated into or combined with one or more steps of any other process or embodiment described herein.

[0111] Step 1302 may include the battery management module receiving capability information from a battery charging system (e.g., a battery charger) coupled to the battery pack using a control circuit system. In some embodiments, the battery management module may communicate with the battery charger when the battery charger is coupled to one or more battery modules. For example, the electric vehicle may be coupled to the battery charger using a SAE J1772 type connector. The connector may include two or more pins for conducting charging current (e.g., a pin for AC charging, a pin for DC fast charging), a pin for grounding, one or more pins for communication, any other suitable pins, or any combination thereof. In some embodiments, the OBC may communicate with the battery charger and transmit corresponding information to the battery management module. The capability information may include, for example, charging rate, voltage (e.g., charging voltage), current (e.g., maximum charging current rating), time (e.g., a limit on charging time), whether the battery charger has fast charging capability, any other suitable information about the capabilities of the battery charger, or any combination thereof. The battery management module can receive the capacity information as an analog signal (e.g., voltage), a digital signal (e.g., information on a serial port), a modulated signal (e.g., a square wave on top of a DC signal or carrier), a message (e.g., from a TCP connection), any other suitable signal, or any combination thereof.

[0112] Step 1304 may include the battery management module determining whether the battery charging system is capable of fast charging based on the capability information. In some embodiments, the battery management module may receive capability information corresponding to a charging voltage. For example, the battery management module may receive capability information including 900V as a maximum charging voltage. Thus, the battery management module may determine that the battery charger is capable of fast charging (e.g., charging at 900V). In some embodiments, the battery management module may receive capability information corresponding to an available state of the battery charger. For example, the battery management module may receive a signal corresponding to being capable of fast charging (e.g., an alphanumeric code, an alphanumeric identifier, a flag value, or other identifier).

[0113] Step 1306 may include the battery management module applying a switch configuration to at least one mode switch for fast charging using a control circuit system in response to determining that the battery charging system is capable of fast charging. In some embodiments, step 1306 may include the battery management module sending one or more signals to one or more corresponding switches to change the switch position. For example, the battery management module may send a TTL signal to a relay or contactor to change the position. In another example, the battery management module may send a DC signal (e.g., 5V, 12V, 24V, or other voltage) to one or more relays or contactors to change the position. In another example, the battery management module may send an AC signal (e.g., 110VAC, 24VAC, or other voltage) to one or more relays or contactors to change the position. In another example, the battery management module may send a command to a relay or contactor (e.g., which may include a control circuit system) via a CANbus to change the position. In some embodiments, step 1306 may include the battery management module not changing one or more switches when changing the switch configuration. For example, when the switch configuration is applied, one or more switches may remain in one position when changing the coupling of the electrical load from the first battery module to the second battery module. Reference Figure 4 and 6 , if the battery management module applies the switch configuration to change from arrangement 400 to arrangement 600, switches 256, 260, and 262 remain in the same position.

[0114] In an illustrative example, the battery management module may be able to apply a first switch configuration that couples the first battery module and the second battery module in series, and a second switch configuration that couples the first battery module and the second battery module in parallel. At step 1302, the battery management module may receive information including available charging voltages and currents that may be delivered. At step 1304, the battery management module may determine that the battery charger is capable of fast charging (e.g., high voltage charging) based on the available voltage. At step 1306, the battery management module may apply a configuration similar to Figure 4 The switches of the arrangement 400 are configured to perform fast charging on the first and second battery modules.

[0115] expected Fig.13 The steps or descriptions of can be used with any other embodiment of the present disclosure. Fig.13 The steps and descriptions described may be performed in alternative orders or in parallel to further achieve the objectives of the present disclosure. For example, each of these steps may be performed in any order or in parallel or substantially simultaneously to reduce the lag of the system or method or to increase the speed of the system or method. Any of these steps may also be skipped or omitted from the process. In addition, it should be noted that with respect to Figure 1-10Any of the devices or equipment discussed may be used alone or in combination to perform Fig.13 One or more steps in .

[0116] The battery management module can manage the charging of the battery pack based on the battery charger capability information and the local charging information. In order to balance utilization and utilize fast charging when desired (or available), the battery management module can determine and apply a switch configuration to manage charging. For example, the battery management module can determine whether to connect battery modules in series or in parallel based on whether fast charging is available at the charger and whether fast charging is desired by the user or appropriate for the battery pack. Fig.14 is a flow chart of an illustrative process 1400 for managing battery charging of a battery pack based in part on local charging information according to some embodiments of the present disclosure. The battery pack may include, for example, a first battery module and a second battery module. It should be noted that the process 1400 or any of its steps may be performed in Figure 1-10 In addition, one or more steps of process 1400 may be incorporated into or combined with one or more steps of any other process or embodiment described herein.

[0117] Step 1404 may include the battery management module receiving battery charging system capability information from the battery charging system using the control circuit system. In some embodiments, the OBC may communicate with the battery charger and transmit corresponding information to the battery management module. The capability information may include, for example, charging rate, voltage (e.g., charging voltage), current (e.g., maximum charging current rating), time (e.g., limit on charging time), whether the battery charger has a fast charging function, any other suitable information about the battery charger capabilities, or any combination thereof. The battery management module may receive the capability information as an analog signal (e.g., voltage), a digital signal (e.g., information on a serial port), a modulated signal (e.g., a square wave on top of a DC signal or carrier), a message (e.g., from a TCP connection), any other suitable signal, or any combination thereof.

[0118] In some embodiments, step 1404 may include the battery management module using the control circuit system to identify that the battery charging system is coupled to the battery pack. Figure 1 , the battery management module 138 alone or in combination with the onboard charger 146 can recognize that the battery charger 110 is coupled to the battery pack 122 .

[0119] Step 1406 may include the battery management module retrieving local charging information about the battery pack. The local charging information may include, for example, an operating voltage of the battery pack, an operating voltage of a battery module, a maximum charging current, a desired charging mode (e.g., slow charging or fast charging), a desired charging voltage (e.g., low voltage or high voltage), a user preference, a status of one or more battery modules, historical charging information, location information, any other suitable information, or any combination thereof. For example, the local charging information may include a user preference to select fast charging when available. In another example, the local charging information may include an option (e.g., selected by a user) regarding whether to apply fast charging or slow charging. In another example, the local charging information may include a battery module operating voltage of 450V. In another example, the local charging information may include the number of fast charges that have been performed over a period of time (e.g., three fast charges in the last month, or ten fast charges in the life of the battery pack). In another example, the local charging information may include which battery module is coupled to the electrical load during charging.

[0120] In some embodiments, the local charging information may include the location of the battery pack, vehicle, or user. For example, the local charging information may include global positioning system (GPS) information, a set of coordinates, an address (e.g., a place of business or residence), a user-defined location (e.g., received as user input to the battery management module or its interface), an identifier of a battery charger with a location (e.g., a serial number), any other suitable location information, or any combination thereof.

[0121] The battery management module may retrieve the local charging information from local memory (e.g., in a hard drive or solid-state memory), remote memory (e.g., stored in a network cloud-based storage system), any other suitable memory accessible to the battery management module, or any combination thereof. The local charging information may be stored in any suitable format, such as, for example, a database, a lookup table, a collection of flags, one or more ASCII characters or words (e.g., in a text file), any other format, or any combination thereof.

[0122] Step 1408 may include the battery management module determining a switch configuration of at least one switch based at least in part on the battery charging system capability information and the local charging information to connect the first battery module and the second battery module in series or in parallel. In some embodiments, the battery management module may retrieve local charging information, which may include the location of the battery pack. If the location is at the user's home, the battery management module may, for example, determine a switch configuration for slow charging. In another example, if the location is away from or far from the user's home, the battery management module may determine a switch configuration for fast charging. In some cases, fast charging may degrade the battery pack (e.g., have an adverse long-term effect on the battery pack). Thus, it may be desirable to limit the number of fast charging cycles experienced by the battery pack or its battery modules. In some embodiments, the battery management module may, for example, determine a switch configuration for fast charging when the local charging information indicates that the battery pack (e.g., of an electric vehicle) is located along an interstate or at a rest stop (e.g., on the road). Thus, the user may prefer not to wait longer to allow slow charging to complete, but rather to charge quickly to get back on the road. In another example, the battery management module may track (e.g., store in a retrievable memory) the charging history of the battery pack and use the charging history to determine the switch configuration. In an illustrative example, when the local charging information indicates that the user is "on the road", the battery management module may determine the switch configuration for fast charging, unless the total number of fast charges is above a threshold, in which case the battery management module may determine the switch configuration for slow charging. In some embodiments, the local charging information may include the frequency of fast charges, the number of fast charges per time, the battery module capacity, a battery health metric (e.g., whether fast charging has a measurable, detrimental effect), any other suitable historical charging information, or any combination thereof.

[0123] Step 1410 may include the battery management module applying the switch configuration to at least one switch. In some embodiments, step 1410 may include the battery management module sending one or more signals to one or more corresponding switches to change the switch position. In some embodiments, step 1410 may include the battery management module not changing one or more switches when the switch configuration is changed. For example, when applying the switch configuration, one or more switches may remain in one position when changing the coupling of the electrical load from the first battery module to the second battery module. Figure 4 and 6 , if the battery management module applies the switch configuration to change from arrangement 400 to arrangement 600, switches 256, 260, and 262 remain in the same position.

[0124] expected Fig.14 The steps or descriptions of can be used with any other embodiment of the present disclosure. Fig.14 The steps and descriptions described may be performed in alternative orders or in parallel to further achieve the objectives of the present disclosure. For example, each of these steps may be performed in any order or in parallel or substantially simultaneously to reduce the lag of the system or method or to increase the speed of the system or method. Any of these steps may also be skipped or omitted from the process. In addition, it should be noted that with respect to Figure 1-10 Any of the systems or corresponding components discussed may be used alone or in combination to perform Fig.14 One or more steps in .

[0125] The battery management module can manage the overall operation of a battery pack having two or more battery modules. In order to balance utilization and take advantage of fast charging when desired (or available), the battery management module can determine and apply switch configurations to manage charging, operation, fault tolerance, or a combination thereof. For example, the battery management module can determine whether to connect battery modules in series or in parallel based on whether fast charging is available at the charger and whether fast charging is desired by the user or appropriate for the battery pack. In another example, the battery management module can provide fault tolerance during operation even when not charging. Fig.15 is a flow chart of an illustrative process 1500 for managing a battery pack according to some embodiments of the present disclosure. It should be noted that the process 1500 or any of its steps may be performed in any manner. Figure 1-10 In addition, one or more steps of process 1500 may be incorporated into or combined with one or more steps of any other process or embodiment described herein.

[0126] Step 1502 may include the battery management module determining whether a battery charger (e.g., battery charger 1503) is connected to a battery pack, an electric vehicle, a terminal of a battery management module, any other suitable terminal, or any combination thereof. In some embodiments, the battery management module may include a proximity switch, a collection of contacts, a communication interface, or a combination thereof to determine whether the battery charger is connected. For example, a battery charging cable that connects an electric vehicle to a battery charger may include a connector having one or more contacts that are opened or closed when connected to a charging receptacle of the electric vehicle. In another example, the battery management module may determine that the battery charger is connected based on receiving a signal (e.g., an analog signal or a digital signal) from the battery charger. In another example, the battery management module may determine that the battery charger is connected based on receiving a signal (e.g., an analog signal or a digital signal) from an OBC that can communicate with the battery charger.

[0127] Step 1518 may include the battery management module determining one or more battery characteristics corresponding to one or more battery modules, one or more battery packs, or a combination thereof. The battery characteristics may include, for example, a value (e.g., a voltage across a first battery module), a duration, a charge start time, a state (e.g., a state identifier), a time elapsed since the last charge, a time elapsed since the last load, a total number of charges, a cumulative charge time, a battery module capacity, any other suitable metric, or any combination thereof. The battery management module may determine the one or more characteristics during normal operation (e.g., when the electric vehicle is traveling on a road), during charging (e.g., when the battery pack is coupled to a battery charger), during an off period (e.g., when the electric vehicle is parked), or any combination thereof.

[0128] Step 1520 may include the battery management module determining whether a fault has occurred corresponding to one or more battery modules, battery packs, electrical components coupled to the battery modules, any other suitable equipment that may affect operation, or any combination thereof. Step 1520 may be performed during operation, during an off period (e.g., when the electric vehicle is parked), but not necessarily during charging. For example, the battery management module may perform step 1520 continuously or at predetermined intervals to quickly identify a fault. In some embodiments, the battery management module may perform Fig.12 The battery management module may proceed to step 1512 to determine whether a fault has occurred and which battery module is affected. If no fault has occurred, is detected, or is determined to have occurred, the battery management module may proceed to step 1512. If the battery management module determines that a fault has occurred, the battery management module may also proceed to step 1512 to determine a switch configuration based on whether a fault has occurred and which fault has occurred. For example, in the event of a fault, the battery management module may determine a switch configuration that isolates or otherwise reduces the impact of the fault on the battery pack.

[0129] Step 1504 may include the battery management module receiving battery charger information. In some embodiments, the battery management module may receive battery charger information from a battery charger (e.g., battery charger 1503), an OBC of the electric vehicle (e.g., Figure 1 The battery management module may receive charging system information from an onboard charger 146, any other suitable information source, or any combination thereof. In some embodiments, the battery management module may perform steps 1502 and 1504 as a single step. For example, when connected, the battery management module may receive a communication from a battery charger that may include battery charger information, and accordingly the battery management module may determine that the battery charger is connected.

[0130] Step 1506 may include the battery management module determining one or more battery characteristics corresponding to one or more battery modules, one or more battery packs, or a combination thereof. The battery characteristics may include, for example, a value (e.g., a voltage across a first battery module), a duration, a charge start time, a state (e.g., a state identifier), a time elapsed since the last charge, a time elapsed since the last load, a total number of charges, a cumulative charge time, a battery module capacity, any other suitable metric, or any combination thereof.

[0131] Step 1508 may include the battery management module retrieving local charging information. In some embodiments, the battery management module may retrieve the local charging information from a memory (e.g., stored locally). In some embodiments, the battery management module may retrieve the local charging information by receiving information from one or more other subsystems. For example, the battery management module may retrieve information from the OBC (e.g., by submitting a query), including user preference information.

[0132] Step 1510 may include the battery management module determining whether a fault has occurred corresponding to one or more battery modules, battery packs, electrical components coupled to the battery modules, any other suitable equipment that may affect charging, or any combination thereof. In some embodiments, the battery management module may perform Fig.12 The battery management module may proceed to step 1512 to determine whether a fault has occurred and which battery module is affected. If no fault has occurred, is detected, or is determined to have occurred, the battery management module may proceed to step 1511, step 1512, or both if the battery management module determines that a fault has occurred. For example, in the event of a fault, the battery management module may transmit information corresponding to the fault to a battery charger and determine a switch configuration that isolates or otherwise reduces the impact of the fault on the battery pack.

[0133] Step 1511 may include the battery management module transmitting charging information to the battery charger. For example, the battery management module may transmit local charging information to the battery charger 1503. The charging information may include, for example, information about charging progress (e.g., whether the battery pack is fully charged), voltage limits, current limits, fault occurrences, charging time, any other suitable charging information, any changes thereto, or any combination thereof. In some embodiments, the battery management module may transmit the charging information to the battery charger to ensure safe, efficient, repeatable, optimal, and timely charging of the battery pack or one or more modules thereof.

[0134] Step 1512 may include the battery management module determining a switch configuration for at least one switch. The battery management module may determine the switch configuration based at least in part on battery charger information, one or more battery characteristics, local charging information, fault occurrences, any other suitable information, or any combination thereof. In some embodiments, the battery management module may determine a set of one or more switch positions or "throws" and their schedules to provide desired connectivity between terminals of an electrical load, a battery charger, two or more battery modules, a pre-charge circuit, a measurement circuit system, any other suitable component, or any combination thereof. For example, the switch configuration may include one or more switch positions, a schedule for when to apply each switch position, a schedule for when to pre-charge and how long to pre-charge, a schedule for when to perform measurements and how long to perform measurements, and any other suitable information for managing the configuration of one or more switches. At least one switch may include, for example, one or more SPST switches, one or more SPDT switches, any other suitable switches (e.g., DPDT switches), or combinations thereof. At least one switch may include a mechanical relay, a solid-state relay, a contactor, a transistor, any other suitable switching device that can be controlled, or any combination thereof.

[0135] Step 1514 may include the battery management module determining whether to change an existing switch configuration of at least one switch. In some embodiments, the battery management module may store, record, retrieve, or otherwise find available existing switch configurations. In some embodiments, the battery management module may compare the existing switch configuration with the determined switch configuration to determine whether any of the at least one switch will need to change switch positions. For example, the switch configurations may be stored as a vector of switch position values ​​(e.g., integers corresponding to each available switch position), and the battery management module may compare the determined switch configuration vector with the existing switch configuration vector to determine whether any switches are to be changed (e.g., by subtracting the vectors and identifying non-zero values). In another example, the battery management module may loop through a list of switches, checking whether there are differences between the existing switch configuration and the determined switch configuration. If no changes to the switch configuration are applied (e.g., the switches remain in the existing configuration), the battery management module may, for example, return to any of steps 1502, 1504, 1506, 1508, 1510, 1520, 1511, or 1512. For example, if Fig.15 As shown in , the battery management module can return to step 1502.

[0136] In some embodiments, step 1514 may be optional, combined with step 1512, or otherwise omitted. For example, the battery management module may determine a switch configuration and apply the switch configuration without determining whether the determined switch configuration is different from an existing switch configuration. In another example, the battery management module may determine a change to an existing switch configuration at step 1512 (e.g., rather than determining a new switch configuration) and then apply the change at step 1516.

[0137] Step 1516 may include the battery management module applying the switch configuration to at least one switch. For example, the battery management module may apply the switch configuration determined at step 1512 to at least one switch. In some embodiments, the battery management module may include a control circuit system configured to change the position of one or more switches (e.g., apply the switch configuration). In some embodiments, the battery management module may change the position of two or more switches simultaneously or at different times. In some embodiments, the battery management module may change the position of a subset of switches simultaneously and change the position of another non-overlapping subset of switches at a different time. For example, the battery management module may apply the switch configuration to one or more load switches at a first time, apply the switch configuration to one or more mode switches at a second time, and apply the switch configuration to one or more charging switches at a third time. In some embodiments, the battery management module may apply a pre-charge to at least one switch to reduce inrush current when applying the switch configuration. In some embodiments, after applying the switch configuration at step 1516, the battery management module may return to any one of steps 1502, 1504, 1506, 1508, 1510, 1520, or 1511. For example, as Fig.15 As shown in , the battery management module can return to step 1502.

[0138] In the illustrative example, reference Fig.15 In the process 1500, the battery management module can manage low voltage charging or high voltage charging. The battery charger can be connected to an electric vehicle battery pack having at least two battery modules operating at a nominal 450V, for example, via a cable having a connector compliant with SAE J1772, wherein the connector has an AC charging pin, a DC charging pin, a ground pin, a proximity pilot signal pin, and a control pilot signal pin.

[0139] The battery management module can determine that a battery charger is connected, for example, at step 1502 by monitoring the impedance (e.g., resistance) of a proximity pilot signal pin. For example, the proximity pilot signal pin can be coupled to a latch or clip and take a first value when the connector is disconnected, a second value when the connector is connected but the latch is pressed, and a third value when the connector is connected and the latch is closed (e.g., ready for charging). In some embodiments, at step 1504, the battery management module receives a 1kHz square wave from the battery charger, within a range of ±12V. The duty cycle of the square wave can correspond to the maximum available current that the battery charger can provide. In some embodiments, the battery charger information can also include a charging voltage that is available or can be selected for charging.

[0140] The battery management module, upon receiving a signal from the battery charger (e.g., via a control pilot signal pin), can determine local battery characteristics, such as, for example, the voltage across the positive and negative terminals of each battery module. The battery management module can obtain local charging information, such as, for example, whether fast charging is desired. The battery management module can determine at step 1510 (e.g., based on the voltage across each battery module) whether a fault has occurred, and if no fault has occurred, determine a switch configuration. If the battery charger is capable of providing a high voltage (illustratively 900V in this example) and no fault is detected, the battery management module can determine a switch configuration (e.g., similar to 100V) that couples the two battery modules in series and couples the vehicle electrical load to the first battery module. Figure 4 The battery management module may then apply the switch configuration to one or more switches (e.g., to achieve Figure 4 arrangement 400) to start charging.

[0141] While charging, the battery management module may repeat step 1506 and determine that the voltage across the second battery module is greater than the voltage across the first battery module. Thus, the battery management module may determine at step 1512 a switch configuration that maintains the two battery modules connected in series but couples the electrical load to the second battery module (e.g., similar to Figure 5 The battery management module may then apply the switch configuration to at least one switch to implement an arrangement similar to arrangement 500, for example.

[0142] expected Fig.15 The steps or descriptions of can be used with any other embodiment of the present disclosure. Fig.15The steps and descriptions described may be performed in alternative orders or in parallel to further achieve the objectives of the present disclosure. For example, each of these steps may be performed in any order or in parallel or substantially simultaneously to reduce lag or increase the speed of the system or method. Any of these steps may also be skipped or omitted from the process. In addition, it should be noted that with respect to Figure 1-10 Any of the systems discussed may be used alone or together to perform Fig.15 One or more steps in .

[0143] The above-described embodiments of the present disclosure are presented for purposes of illustration and not limitation, and the present disclosure is limited only by the following claims. Figure 1-10 Any of the equipment or devices discussed may be used to perform Figure 11-15 In the process 1100-1500 of one or more steps. In addition, it should be noted that the features and limitations described in any one embodiment can be applied to any other embodiment herein, and the flowcharts or examples associated with one embodiment can be combined with any other embodiment in an appropriate manner, completed in a different order, performed with added steps, performed with omitted steps, or performed in parallel. For example, each of these steps can be performed in any order or in parallel or substantially simultaneously to reduce the lag of the system or method or increase the speed of the system or method. In addition, the systems and methods described herein can be executed in real time. It should also be noted that the above-mentioned systems and / or methods can be applied to other systems and / or methods, or used according to other systems and / or methods.

[0144] The foregoing is merely an example of the principles of the present disclosure, and various modifications may be made by those skilled in the art without departing from the scope of the present disclosure. The above embodiments are given for illustration rather than limitation. In addition to the forms explicitly described herein, the present disclosure may also take many forms. Thus, it is emphasized that the present disclosure is not limited to the methods, systems, and devices explicitly disclosed, but is intended to include changes and modifications thereto within the spirit of the following claims.

Claims

1. A method for managing battery charging of a first battery module and a second battery module coupled in series, comprising: using at least one switch in a first switch configuration to couple an electrical load in parallel to the first battery module during charging; determining, using the battery management module, a first battery characteristic of the first battery module during charging, wherein the first battery characteristic includes a first voltage across a positive terminal and a negative terminal of the first battery module; determining, using the battery management module, a second battery characteristic of the second battery module during charging, wherein the second battery characteristic includes a second voltage across a positive terminal and a negative terminal of the second battery module; using a battery management module, determining to apply a second switch configuration to the at least one switch based on a first battery characteristic and a second battery characteristic, wherein the second switch configuration couples an electrical load in parallel to the second battery module during charging, and wherein determining to apply the second switch configuration to the at least one switch based on the first battery characteristic and the second battery characteristic comprises determining a difference between the first voltage and the second voltage; as well as Using the control circuitry, a second switch configuration is applied to the at least one switch. 2 . The method of claim 1 , further comprising determining local charging information, wherein the local charging information includes a preference for charging at a high voltage.

3. The method of claim 2, further comprising determining to serially couple the first battery module and the second battery module based at least in part on the local charging information.

4. The method of claim 1, wherein applying a second switch configuration to the at least one switch further comprises applying a precharge configuration to the at least one switch to reduce inrush current.

5. A method for managing battery charging of a first battery module and a second battery module coupled in series, comprising: using at least one switch in a first switch configuration to couple an electrical load in parallel to the first battery module during charging; determining, using the battery management module, a first battery characteristic of the first battery module during charging, wherein the first battery characteristic comprises a first accumulated time that the first battery module is coupled to the electrical load; determining, using the battery management module, a second battery characteristic of the second battery module during charging, wherein the second battery characteristic includes a second accumulated time that the second battery module is coupled to the electrical load; determining, using the battery management module, to apply a second switch configuration to the at least one switch based on the first battery characteristic and the second battery characteristic, wherein the second switch configuration couples the electrical load in parallel to the second battery module during charging; as well as Using the control circuitry, a second switch configuration is applied to the at least one switch. 6 . The method of claim 5 , wherein determining to apply a second switch configuration to the at least one switch based on the first battery characteristic and the second battery characteristic comprises determining a difference between the first accumulated time and the second accumulated time. 7 . The method of claim 5 , further comprising determining local charging information, wherein the local charging information includes a preference for charging at a high voltage.

8. The method of claim 7, further comprising determining to serially couple the first battery module and the second battery module based at least in part on the local charging information.

9. The method of claim 5, wherein applying a second switch configuration to the at least one switch further comprises applying a precharge configuration to the at least one switch to reduce inrush current.

10. A method for managing battery charging of a first battery module and a second battery module coupled in series, comprising: using at least one switch in a first switch configuration to couple an electrical load in parallel to the first battery module during charging; determining, using the battery management module, a first battery characteristic of the first battery module during charging; determining, using the battery management module, a second battery characteristic of the second battery module during charging; determining, using the battery management module, to apply a second switch configuration to the at least one switch based on the first battery characteristic and the second battery characteristic, wherein the second switch configuration couples the electrical load in parallel to the second battery module during charging; applying, using the control circuitry, a second switch configuration to the at least one switch; as well as Identifying whether a fault has occurred in the first battery module or the second battery module, wherein determining to apply the second switch configuration to the at least one switch based on the first battery characteristic and the second battery characteristic is also based at least in part on whether the fault has occurred. 11 . The method of claim 10 , further comprising determining local charging information, wherein the local charging information includes a preference for charging at a high voltage.

12. The method of claim 11, further comprising determining to serially couple the first battery module and the second battery module based at least in part on the local charging information.

13. The method of claim 10, wherein applying a second switch configuration to the at least one switch further comprises applying a precharge configuration to the at least one switch to reduce inrush current.

14. A method for managing battery charging of a first battery module and a second battery module coupled in series, comprising: using at least one switch in a first switch configuration to couple an electrical load in parallel to the first battery module during charging; determining, using the battery management module, a first battery characteristic of the first battery module during charging; determining, using the battery management module, a second battery characteristic of the second battery module during charging; determining, using the battery management module, to apply a second switch configuration to the at least one switch based on the first battery characteristic and the second battery characteristic, wherein the second switch configuration couples the electrical load in parallel to the second battery module during charging; applying, using the control circuitry, a second switch configuration to the at least one switch; as well as A time that has elapsed since a previous change in the switch configuration is determined, wherein determining to apply the second switch configuration to the at least one switch based on the first battery characteristic and the second battery characteristic is also based at least in part on the elapsed time. 15 . The method of claim 14 , further comprising determining local charging information, wherein the local charging information includes a preference for charging at a high voltage.

16. The method of claim 15, further comprising determining to serially couple the first battery module and the second battery module based at least in part on the local charging information.

17. The method of claim 14, wherein applying a second switch configuration to the at least one switch further comprises applying a precharge configuration to the at least one switch to reduce inrush current.

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