Deviation detection system for energy storage system

Abstract

A system (100) includes a first set (110) of sensors (103) and a control circuit (104) including one or more processors (120). The first set of sensors is associated with an energy storage module (106) having one or more energy storage devices (108). The sensors in the first set generate sensor measurements (304) representing one or more parameters of the energy storage module. The control circuit is configured to receive the sensor measurements and determine one or more reference values ​​(302, 408) or reference changes for a particular parameter associated with the energy storage module based at least in part on the sensor measurements. The control circuit compares one or more monitored values ​​(406A-F) or monitored changes for the particular parameter with the reference value or reference change for the particular parameter based on the sensor measurements generated by the sensors, and detects deviations greater than a specified tolerance (410).

Description

Technical Field

[0001] The subject matter described herein relates to deviation detection systems for use with energy storage systems. Background Art

[0002] Energy storage systems can utilize a large number of battery cells, which can be difficult to manage and monitor. A failure in one battery cell or module of multiple battery cells can be undesirable and result in secondary damage to other batteries within the same or different modules. Known systems for monitoring energy storage systems compare sensor measurements to preset absolute limits or thresholds and trigger an action / alarm condition if one or more of these sensor measurements exceeds a corresponding preset limit (such as a preset temperature threshold). However, such known systems can be relatively inaccurate and / or slow to detect potential failures because the failure remains undetected until the preset limit is crossed. Furthermore, such known systems may provide little additional information that can be used to mitigate damage, such as the location of the failure (e.g., which specific cells among thousands of cells are affected), the type of failure (e.g., fire, bad weld, sensor malfunction, etc.), and so forth, to provide service or isolate the affected portion of the storage system. It would be desirable to have a method and / or system for early detection of failures and additional information related to the failure to protect the energy storage system and mitigate secondary damage. Summary of the Invention

[0003] In one or more embodiments, a system is provided that includes a first group of sensors and a control circuit including one or more processors. The first group of sensors is associated with an energy storage module including one or more energy storage devices. The sensors in the first group are configured to generate sensor measurements representing one or more parameters of the energy storage module. The control circuit is configured to receive the sensor measurements generated by the sensors and determine one or more reference values ​​or reference changes of a specific parameter related to the energy storage module based at least in part on the sensor measurements. The control circuit is configured to compare one or more of the monitored values ​​or monitored changes of the specific parameter with a reference value or reference change of the specific parameter based on the sensor measurements generated by the sensors in the first group, and to detect deviations greater than a specified tolerance margin.

[0004] In one or more embodiments, a method is provided, the method comprising: obtaining sensor measurements generated by a first group of sensors associated with an energy storage module. The energy storage module comprises one or more energy storage devices. The sensor measurements represent one or more parameters of the energy storage module. The method comprises: comparing one or more of the monitored values ​​or monitored changes of a particular parameter associated with the energy storage module with one or more of the reference values ​​or reference changes of the particular parameter. Both one or more of the monitored values ​​or monitored changes and one or more of the reference values ​​or reference changes are based, at least in part, on the sensor measurements generated by the first group of sensors. The method comprises: detecting a deviation condition in response to one or more of the monitored values ​​or monitored changes deviating from the reference value or reference change by more than a specified tolerance. The method further comprises: identifying a first sensor in the first group that generated the sensor measurement on which the deviated monitored value or monitored change is based; and estimating a cause of the deviation condition based, at least in part, on the sensor measurements generated by the first sensor.

[0005] In one or more embodiments, a system is provided that includes a control circuit having one or more processors. The control circuit is configured to obtain sensor measurements generated by a first group of sensors associated with an energy storage module that includes one or more energy storage devices. The sensor measurements represent one or more parameters of the energy storage module. The control circuit is configured to compare the sensor measurements representing a particular parameter of the one or more parameters with one or more of a reference value for the particular parameter or a reference change for the particular parameter. In response to detecting that one or more of the sensor measurements deviate from the reference value or reference change by more than a specified tolerance, the control circuit is configured to: identify a first sensor in the first group that generated at least some of the one or more deviated sensor measurements; estimate a cause of the deviation based at least in part on the sensor measurements generated by the first sensor; and generate a control signal based on the estimated cause to initiate one or more remedial actions. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Reference is now briefly made to the accompanying drawings, in which:

[0007] Figure 1 is a schematic diagram of a deviation detection system according to an embodiment of the present invention;

[0008] Figure 2 is a schematic diagram of a vehicle system incorporating a deviation detection system according to an embodiment;

[0009] Figure 3is a block flow diagram illustrating the operation of a control circuit of a deviation detection system according to an embodiment;

[0010] Figure 4 is a graph plotting sensor measurements generated by a temperature sensor associated with an energy storage module according to an embodiment; and

[0011] Figure 5 is a flow chart of a method for detecting and responding to a deviation condition in an energy storage system according to an embodiment. DETAILED DESCRIPTION

[0012] One or more embodiments described herein provide a system and method for deviation detection during operation of an energy storage system. Some of the deviation detection systems and methods described herein may be based on modeling / observing an expected (or reference) behavior of an energy storage module and detecting a deviation condition based on a deviation between the monitored behavior of the energy storage module and the expected behavior. The expected behavior may be determined in the form of a parameter value, a parameter value over time (e.g., a plotted line), a change in a parameter value over time (e.g., a slope), a change in a parameter value (e.g., a range), and the like. The parameters used to represent the expected behavior may be measurement parameters that can be directly measured by a sensor, and / or derived parameters or transformed parameters that can be derived as a function of the sensor measurements. As used herein, parameter values ​​and parameter changes that represent the expected behavior are referred to as reference values ​​and reference changes.

[0013] Certain items within a group that experience similar operating conditions can be expected to perform similarly. For example, temperature sensors monitoring the temperature of different battery cells in the same module can be expected to generate similar temperature measurements. Furthermore, temperature sensors in different modules that may be exposed to similar environmental conditions, states of charge, and power loads can be expected to generate similar temperature measurements. Conversely, if two energy storage modules experience known differences in operating conditions during a shared vehicle experience, an expected (or reference) temperature difference between the two energy storage modules can be determined. Thus, if at least one of the temperature sensors records a temperature measurement that deviates from the expected temperature measurement, the difference indicates a possible malfunction associated with the battery cell, sensor, or another component of the energy storage system. While absolute temperatures may be mentioned in these examples, temperature-based derivatives, including the rate of change of temperature, are also contemplated in embodiments herein. Furthermore, embodiments disclosed herein also contemplate parameters other than temperature, such as voltage, power, current, and the like.

[0014] In contrast to known energy storage monitoring systems, which detect alarm conditions based on measured values ​​of parameters that cross preset absolute limits or thresholds, deviation conditions can be detected based on excessive deviations from expected (or reference) behavior. The deviation detection system disclosed herein can provide earlier detection of potential faults than known systems. For example, if a known system has a preset temperature threshold of 40 degrees Celsius (°C), the known system will not detect a potential fault until a sensor generates a temperature measurement of at least 40°C. However, the deviation detection system described herein may be able to detect a potential fault before the temperature exceeds 40°C. For example, if a measured temperature value deviates from a reference (e.g., expected) value of temperature, or a reference change (or variance) in temperature, by more than a specified tolerance, the deviation detection system will detect a deviation condition even though the measured temperature value may be less than 40°C. Earlier detection can enable the deviation detection system to prevent or at least reduce the extent of damage caused by the failure of one or more battery cells (such as fire or thermal runaway) and / or the failure of other components (such as sensors).

[0015] In addition to providing early detection of potential faults in energy storage systems, the deviation detection systems disclosed herein can also provide additional information useful for locating, diagnosing, and mitigating damage and delays. For example, the deviation detection system can identify one or more specific sensors that generated deviating sensor measurements that triggered a deviation condition, thereby allowing for precise localization of the potential fault. Furthermore, upon detecting a deviation condition, the deviation detection system can automatically initiate one or more response or remedial actions to prevent or at least mitigate the spread of damage due to fire, thermal runaway, and the like. Response actions can include isolating one or more energy storage modules by blocking current flow to and from the energy storage module(s), initiating active cooling, initiating fire suppression, and the like. The deviation detection system can also analyze deviating sensor measurements based on expected behaviors associated with different specific fault conditions, utilizing sensor measurements representing the same parameters and / or different parameters, to estimate the cause of the deviation condition. For example, the deviation detection system can estimate that the deviation condition may be caused by a malfunctioning energy storage device (e.g., a battery cell), a malfunctioning sensor, a bad solder joint, a short circuit, a malfunctioning cooling system, a broken tab connecting two energy storage devices, and the like.

[0016] The estimation of the cause of the deviation condition enables the deviation detection system to take, or at least suggest, remedial actions specific to the fault. For example, if the cause can be estimated to be a malfunctioning sensor, the deviation detection system can mark the sensor for repair or replacement, and / or ignore or substitute future measurements from the sensor. On the other hand, if the cause can be estimated to be a malfunctioning battery cell that is experiencing (or is at risk of experiencing) a fire or thermal runaway, the deviation detection system can isolate the battery cell, initiate active cooling, and the like, to prevent the spread of secondary damage from the battery cell. Thus, rather than simply providing a general alert when an absolute limit or threshold may be crossed, the deviation detection system described herein can provide early detection of an anomaly, as well as additional information such as the location of the anomaly and the estimated type and cause, which can be used to provide enhanced protection and operation of the energy storage system.

[0017] In one or more embodiments, upon detecting a deviation condition, the system can automatically take one or more immediate temporary actions that assume a worst-case scenario. For example, a worst-case scenario could be that the energy storage module may be on fire and / or experiencing thermal runaway. Thus, before estimating the cause of the deviation condition, the system can take immediate action to mitigate the potential damage from the fire and / or thermal runaway, such as by extinguishing the fire, electrically isolating the energy storage module, de-rating the vehicle's performance, and so on. If it is subsequently determined that the cause of the deviation condition may be a faulty sensor or other cause that may be less severe than the worst-case scenario, such that a fire or thermal runaway may not exist, the system can cease and / or modify the temporary actions that may have been based on the worst-case scenario. For example, by modifying the temporary actions when the fire and / or thermal runaway as the cause has been eliminated, the system can increase the load on the energy storage device, maintain vehicle operation, and so on. On the other hand, if it is determined that the energy storage module is faulty, the system can maintain the temporary actions. The deviation detection system's ability to maintain and / or modify actions based on the estimated cause may be advantageous over known systems. For example, known systems that detect a deviation may automatically shut down operation of an energy storage module, vehicle, etc., requiring an operator to perform inspection before enabling additional operations, which may reduce efficiency and significantly slow down the execution of the enumeration task.

[0018] According to one embodiment, the deviation detection system operates according to an algorithm. The first part of the algorithm may be to determine the expected behavior under the assumption that each battery, battery pack, sensor, and / or sensor group will not fail simultaneously. This expected behavior can be developed by incorporating a physics-based model of operating conditions. For example, given certain characteristics of an energy storage module (such as the state of charge and internal impedance of its battery cells), a reference voltage for the energy storage module can be determined. For a certain change in stored current (e.g., per ampere-hour), a certain amount of change in voltage may be expected. In addition to or as an alternative to modeling the expected behavior, the expected behavior can be determined by tracking the history and operation of the energy storage module over time. Furthermore, the expected behavior can be determined by comparing the parameters of an energy storage device (e.g., a battery cell) with the parameters of other energy storage devices in the same module and / or other modules. It can be expected that for a given change in ampere-hour, all series-connected batteries should see a change in voltage in the same direction. In a first non-limiting example, if the voltage decreases for one battery but increases for all other series-connected batteries, a problem can be inferred. In another non-limiting example, if the voltage for one cell may increase much faster than the voltage for all other cells in the same module, the deviation detection system may identify a broken weld as the cause of the deviation. In the same or other examples of deviation detection systems, other parameters besides voltage may be utilized, such as temperature, power, etc.

[0019] The algorithm can utilize multiple different parameters to estimate the cause of a deviation condition. For example, when there is a broken weld, not only should the voltage increase at a faster rate, but the resistance and temperature of the cell should also be greater than other cells in the same module, or greater than cells in another module carrying similar currents. By combining a physics-based model with expectations through comparison, the deviation detection system disclosed herein can distinguish between a sensor failure and an inaccurate model. Some error between reality and the model may be acceptable. Therefore, the deviation detection system also incorporates expected deviations in the form of specified tolerances. Expected deviations may be due to sensor inaccuracies and design changes (such as temperature gradients). Since internal resistance may change over time, expected deviations may also change over the course of the battery cell's operating life. By determining the expected behavior of the parameters and the expected deviations, the deviation detection system can detect when a problem occurs, determine the root cause of the problem, and take appropriate action.

[0020] Figure 11 is a schematic diagram of a deviation detection system 100 according to an embodiment of the present disclosure. The deviation detection system includes a plurality of sensors 103 and a control circuit 104 operatively connected to the sensors 103. The sensors monitor various parameters of the energy storage system 102. The parameters measured by the sensors may include temperature, voltage, current, state of charge, charge capacity, resistance, pressure, coolant flow rate, etc. The coolant may be a fluid such as air or liquid.

[0021] The different parameters listed above can be measured by different sensors, each specifically configured to monitor one or more specific parameters for use by the detection system. For example, temperature can be monitored by one or more temperature sensors (such as thermistors, thermocouples, resistance temperature detectors (RTDs), etc.). The temperature parameter can indicate the temperature of one or more energy storage devices, or the ambient temperature near one or more energy storage devices. Voltage can be monitored by one or more voltage sensors (such as non-contact voltage detectors). The voltage parameter can indicate the voltage supplied to the energy storage module. Current can be monitored by one or more current sensors (such as Hall effect sensors, fluxgate transformer sensors, etc.). The current parameter can indicate the amount of electrical energy flowing into and / or out of the energy storage module. The state of charge can indicate the amount of electrical energy actually present in the energy module (or its devices). The charge capacity can indicate the amount of electrical energy that can be stored within the energy module (or its devices). The state of charge and / or charge capacity can be measured by an integrated battery tester or based on sensor outputs from voltage and current sensors. For example, it may be possible to calculate the state of charge and / or charge capacity based on the measured current and voltage outputs. Resistance can represent the resistance to the flow of current through an electrical energy module (or its devices). Resistance can be measured by utilizing Ohm's law based on sensor outputs from a voltage sensor and a current sensor. Current and voltage sensors can be integrated into a multimeter to measure resistance. Pressure can refer to the ambient pressure surrounding the energy storage module(s) and can be measured by a pressure sensor (such as a pressure transducer, a piezoelectric element, etc.). Coolant flow rate can refer to the flow rate of a cooling fluid (such as air, refrigerant, liquid, gas (other than air), etc.) that is directed to flow across one or more electrical energy modules to absorb and dissipate heat generated by the one or more electrical energy modules. Coolant flow rate can be measured by a flow sensor (such as a moving vane meter, a hot-wire mass flow sensor, a cold-wire mass flow sensor, a membrane sensor, etc.).

[0022] The energy storage system stores energy for use in providing work, such as for propelling a vehicle. The energy storage system includes a plurality of energy storage modules 106. Each energy storage module includes one or more energy storage devices 108 ( Figure 1). The energy storage devices may be battery cells, capacitors, and the like. The energy storage devices in each module may be electrically connected to one another, such as in a series or parallel relationship. In the illustrated embodiment, two energy storage modules 106A, 106B may be shown, and each of the energy storage modules 106A, 106B has an assembly of three energy storage devices. In other embodiments, the energy storage module may include more or less than three energy storage devices, such as only one energy storage device, six energy storage devices, ten energy storage devices, and the like. Although two energy storage modules may be shown, the energy storage system may include additional energy storage modules, such as ten energy storage modules, twenty-five energy storage modules, and the like. Different energy storage modules may be electrically connected to one another, such as in a series or parallel relationship, to define a string. Alternatively, the energy storage modules may be electrically isolated from one another. In an alternative embodiment, the energy storage system may have only one energy storage module, and a single energy storage module may include multiple energy storage devices.

[0023] The deviation detection system can monitor the operation of the energy storage system by analyzing sensor measurements generated by the sensors. For example, the sensors can be arranged in a first group 110 and a second group 112. The first group can be associated with the first energy storage module 106A, and the second group 112 can be associated with the second energy storage module 106B. For example, the sensors in the first group monitor various parameters of the first energy storage module. The various parameters of the first energy storage module include parameters of each of its energy storage devices. In the illustrated embodiment, the sensors in the first group include a temperature sensor 114, a voltage sensor 116, and a current sensor 118. A different pair of temperature sensors can measure the temperature of each of the energy storage devices, so that there can be six temperature sensors in the first group that measure the temperature of three energy storage devices. The first group includes three voltage sensors, each of which is configured to measure the voltage across a different one of the three energy storage devices (or a set of energy storage devices if a parallel arrangement is employed). The first group has a single current sensor that measures the current passing through the first energy storage module. The second energy storage module can be Figure 1 The first energy storage module in the energy storage system may be a replica of the first energy storage module, and the second set of sensors may be a replica of the first set. The type of sensors, number of sensors, and / or placement of sensors may be selected based on application-specific parameters. For example, the first set and / or second set may include sensors for measuring resistance, state of charge, charge capacity, pressure, coolant flow rate, etc. A suitable sensor may be associated with at least one of the energy storage modules of the energy storage system. The proximity, spacing, sensitivity, and type of sensors may be utilized in an application to support various aspects of the present system.

[0024] The control circuitry 104 can obtain and analyze sensor measurements generated by sensors associated with the energy storage system for the purposes of monitoring the operation of the energy storage system and providing efficient and rapid remedial measures to address malfunctions and / or failures in order to limit damage. The control circuitry includes one or more processors 120 and associated circuitry, such as computer processors or other logic-based devices that execute operations based on one or more sets of programmed instructions (e.g., software). The programmed instructions on which the control circuitry operates can be stored on a tangible and non-transitory (e.g., non-transient signals) computer-readable storage medium, such as memory 122. The memory can include one or more computer hard drives, flash drives, RAM, ROM, EEPROM, etc. Alternatively, the instructions directing the operation of the control circuitry 104 can be hardwired into the control circuitry's logic, such as via hardwired logic formed in a field programmable gate array (FPGA), a complex programmable logic device (CPLD), and / or other hardware. In one embodiment, the control circuitry can be conductively connected to the sensors via a conductive path, such as a cable 124, contacts, fiber optic cables, circuit traces, etc., and the control circuitry obtains sensor measurements via the conductive path. Alternatively, at least some of the sensors can be wirelessly connected to the control circuitry, and the sensor measurements can be wirelessly transmitted to the control circuitry 104. The control circuitry obtains sensor measurements generated by sensors in both the first group associated with the first energy storage module and the second group associated with the second energy storage module.

[0025] The control circuitry determines a reference value and / or reference change for a specific parameter based on sensor measurements generated by the sensors. The specific parameter may be a measured parameter that can be directly measured by one or more sensors associated with the energy storage module, such as temperature, voltage, current, etc. Alternatively, the specific parameter may be a derived parameter or transformed parameter that is not directly measured by any of the sensors but rather derived as a function of one or more sensor measurements. A first non-limiting example of a derived parameter may be power, which may be derived from current and voltage sensor measurements. A derived parameter may also include a statistical measure, such as the mean, median, mode, etc., of a measured parameter (e.g., the mean of temperature) or the mean, median, mode, etc., of another derived parameter (e.g., the mean of power). Other non-limiting examples of the specific parameter may include RMS (root mean square) current, harmonic current, state of charge, capacity, resistance, etc. Although the reference value and / or reference change for a single specific parameter may be described herein, it will be appreciated that the control circuitry may determine corresponding reference values ​​and / or changes for a plurality of different specific parameters for use in determining a deviation condition.

[0026] As described in greater detail herein, the reference value and / or reference change can be based on sensor measurements from a first group of sensors monitoring a first energy storage module, sensor measurements from a second group of sensors monitoring a second energy storage module (as well as any additional sensor measurements associated with the energy storage system), operating parameters of the energy storage system, inherent characteristics of the energy storage devices of the storage modules (e.g., battery chemistry), historical information about the energy storage modules (e.g., age, state of health, etc.), and / or historical information observed from other energy storage modules (e.g., trends). The reference value and / or change can change over time.

[0027] There are several ways to determine a reference value for a parameter, including but not limited to comparing parameters within the same module, within the same string, between different strings, between different locomotives, and through physics, or a combination thereof. The control circuitry can use one or more of these methods to determine multiple reference values ​​for the same parameter. Each of these reference values ​​will have an associated value, variance, and / or confidence interval. For example, because the sensors are enclosed in the same package, it can be expected that the temperature of the cells within a module will have a smaller variance than the temperature of the cells within the entire string. Each of the reference values ​​for the same parameter and its associated variance / confidence interval can be combined into a single reference value and reference variance / confidence interval using a transfer function. An example of such a transfer function could be a weighted average, where a greater weight can be assigned to reference values ​​with smaller variances, or a greater weight can be assigned based on the source. For example, a reference value derived from data within a module can be weighted more highly than a reference value derived from data from other modules within the string. Similarly, reference values ​​derived from data within the string (where the module is located) may be weighted more highly than reference values ​​derived from data from modules and / or strings in adjacent string(s).

[0028] To monitor the operation of the first energy storage module, the control circuit receives sensor measurements from the sensors in the first group and determines a monitored value and / or monitored change for a particular parameter based on these sensor measurements. For example, if a reference value and / or reference change in a particular parameter represents a controlled variable, the monitored value and / or change represents an experimental variable. Like the reference value and / or change, the monitored value and / or change for a particular parameter can be a direct sensor measurement or a derived calculation based on a direct sensor measurement. In a non-limiting example, if the particular parameter can be temperature, the control circuit can determine the monitored value as a temperature measurement generated by all corresponding temperature sensors in the first group. In another non-limiting example, if the particular parameter can be power, the control circuit can determine the monitored value as a power calculation derived by multiplying a current measurement by a voltage measurement. The monitored change represents a difference in the monitored values. For example, the monitored change can be equal to the difference between two different power calculations associated with the energy storage module, where the power calculations can be based on different voltage and current measurements.

[0029] After determining the monitored value and / or change, the control circuitry may compare the monitored value and / or change with a reference value and / or change for a specific parameter. For example, if the specific parameter may be temperature, the control circuitry may compare all temperature measurements generated by the temperature sensors in the first group with the reference value and / or reference change. If at least one of the monitored values ​​and / or changes deviates from the reference value and / or reference change by more than a specified tolerance or range, the control circuitry detects a deviation condition. A deviation condition represents a state in which a potential fault may be detected. The term "potential fault" may refer to a broad category of scenarios of varying severity, such as a malfunctioning sensor, a broken / damaged tab connecting an energy storage device, a poor weld, a malfunctioning cooling system, a malfunctioning energy storage device (which may have experienced a fire or thermal runaway), and the like. Upon detecting a deviation condition, the control circuitry may, in accordance with programmed instructions, take one or more responsive actions, such as notifying an operator and / or isolating the energy storage module by at least temporarily preventing current flow to and / or from the energy storage module until the cause of the deviation condition can be determined and remedied.

[0030] Optionally, the control circuitry can be operably connected to a communication device 126, which represents a component of a deviation detection system having control circuitry and sensors. The control circuitry can generate one or more control signals that can be transmitted by the communication device to an intended recipient, such as a vehicle controller, a human operator, or the like. The communication device can include a transceiver (or separate transmitter and receiver components), an antenna 128, and associated circuitry for wireless, two-way communication of various types of messages, such as command messages, reply messages, status messages, and the like. The communication device can transmit messages to specific designated receivers and / or broadcast messages. Optionally, the communication device can include circuitry for transmitting messages over a wired connection, such as between multiple energy storage systems in the same vehicle or between different vehicles that can be electrically coupled.

[0031] Figure 2 2 is a schematic diagram of a vehicle system 200 incorporating a deviation detection system 100 according to an embodiment. The vehicle system moves along a route 204. The vehicle system in the illustrated embodiment represents a vehicle consist. A suitable vehicle consist may include a rail vehicle consist (e.g., a train) having both propulsion-generating vehicles 206 (e.g., vehicles 206A-C) and non-propulsion-generating vehicles 208 (e.g., vehicles 208A-B) mechanically coupled together via couplers 210 (which may optionally include electrical connectors). In this example, the propulsion-generating vehicles may be locomotives, and the non-propulsion-generating vehicles may be railcars.

[0032] Other suitable vehicle formations may include a group of communication-linked on-road vehicles. In one embodiment, the vehicles are remotely controlled or autonomous. A vehicle system may be formed by multiple vehicles that may be physically separate but logically coupled to each other to enable communication among the vehicles to coordinate their movements. Additionally, a suitable vehicle system may be formed by a single propulsion-generating vehicle rather than a plurality of vehicles (whether or not propulsion-generating vehicles).

[0033] Suitable propulsion generating vehicles include a corresponding propulsion system 212 that generates tractive force for propelling the vehicle system along the route. Each propulsion system can have one or more traction motors 213 that are operably coupled to different axles 214 and / or wheels 216 of the vehicle. The traction motors can be connected to the axles and / or wheels via one or more gears, sets of gears, or other mechanical devices to convert the rotational motion generated by the traction motors into rotation of the axles and / or wheels. Different traction motors can be operably connected to different axles and / or wheels such that a traction motor that can be deactivated (e.g., turned off) does not rotate the corresponding axle and / or wheel, while a traction motor that remains activated (e.g., turned on) rotates the corresponding axle and / or wheel. Each propulsion system also includes an energy storage system 202 that provides power to the traction motors. The energy storage system on each propulsion generating vehicle can be connected to Figure 1 The energy storage system 102 shown in FIG. 1 is the same as or similar to the energy storage system 102 shown in FIG. For example, a traction motor in a propulsion state can be powered by current provided to the traction motor by the energy storage system. In a regenerative braking state, the traction motor can provide current generated by the rotation of the wheels and / or axles to the energy storage system for charging its energy storage device (e.g., battery cells, etc.).

[0034] Includes sensors and control circuits (both in Figure 1 A deviation detection system (shown in FIG) can be provided on each of the propulsion generating vehicles to monitor the operation of its energy storage system. Alternatively, a different, separate deviation detection system can be provided on each of the three propulsion generating vehicles. Alternatively, a single control circuit on the vehicle system (e.g., a master control circuit) can obtain sensor measurements from sensors provided on different vehicles to monitor all of the energy storage systems.

[0035] although Figure 2 The deviation detection system is illustrated as being incorporated into a rail vehicle consist, but the embodiments described herein may be applied to other types of vehicle consists and / or vehicles other than rail vehicles, such as off-highway vehicles (e.g., mining vehicles, or other vehicles that may not be designed or permitted for travel on public roads), marine vessels, automobiles, etc. Furthermore, even in stationary industrial, non-vehicle applications, the deviation detection system described herein may be used to monitor any large energy storage system.

[0036] Figure 3is a block flow diagram illustrating the operation of a control circuit of a deviation detection system according to one embodiment. At 302, the control circuit determines a reference value and / or a reference change of a particular parameter. The reference value and / or change represents the expected behavior of the energy storage module (or its energy storage device) that may be being monitored. Energy storage modules in the same energy storage system (or even different energy storage systems) that experience similar operating conditions may be expected to perform similarly and have similar responses to common stimuli (such as, loads or current demands applied to the storage modules). Energy storage devices within the same energy storage module, and across different energy storage modules, may have the same or similar characteristics. These characteristics may include battery chemistry, capacity, type, age / usage / health, batch number, etc. The reference value and / or reference change may be a digital representation of the expected behavior.

[0037] A reference value can be a single numerical value, a numerical value over time (e.g., which can be plotted on a graph as a plotted line), a change in a numerical value over time (e.g., a slope), a rate of change in a numerical value over time, and so on. For example, when the reference value represents temperature over time, at each given time, the sensor measurement of a temperature sensor is expected to be at or near the expected temperature. In one embodiment, a reference variation can represent a calculated difference between two or more data points. For example, a reference variation of 10 degrees can indicate that a group of temperature sensors associated with the same energy storage module should not generate temperature measurements that differ by more than 10 degrees from each other. Therefore, the lowest temperature measurement should be within a reference variation (e.g., 10 degrees) of the highest temperature measurement. The reference variation can vary over time. The reference variation can depend on operating conditions, such as different locations in the system, different voltages in the devices, and so on. For example, if it is known that the energy storage devices have different locations relative to the coolant flow, the reference variation in temperature may be greater than if all devices were equally or approximately equally accessible to the coolant flow. Devices adjacent to the coolant flow are expected to have lower temperatures than devices further from the coolant flow. In another embodiment, the reference variation can represent a range of values. For example, the reference variation can be a range defined between two set points, lines, or planes representing a lower limit and an upper limit. The position of one or both of the upper and lower limits, as well as the magnitude of the range between the upper and lower limits, can change over time.

[0038] The reference value and / or change can be based on various input data received by or accessible to the control circuit. The input data used to determine the reference value and / or change for a particular parameter of the first energy storage module can include, for example, local sensor measurements 304, sensor measurements 306 from other energy storage modules, operating conditions 308, inherent characteristics 310 of the energy storage module, historical information 312 about the first energy storage module, and / or historical information 314 about other energy storage modules.

[0039] Local sensor measurements 304 represent raw data generated by sensors associated with the first energy storage module. Optionally, the control circuitry may filter out or replace some sensor measurements that have low quality, such as low signal-to-noise ratios or clearly erroneous readings (e.g., a temperature measurement from a sensor that does not change over an extended period of time, while it is known from other sensors that the temperature may be changing). If the particular parameter may be temperature, the control circuitry may utilize data from sensors associated with the first energy storage module. Figure 1 The sensor measurement results of all six temperature sensors associated with the first energy storage module are shown in .

[0040] Sensor measurements from other energy storage modules 306 refer to sensor measurements from a second set of sensors associated with a second energy storage module, and may also refer to sensor measurements from other energy storage modules in the same or different energy storage systems. For example, to determine a reference value and / or change in temperature, the control circuitry may obtain temperature measurements from all (or most) temperature sensors throughout the energy storage system and compile the temperature measurements.

[0041] The operating conditions 308 refer to the current environmental conditions and operation of the first energy storage module. For example, the operating conditions may include: ambient temperature, ambient air flow, pressure, humidity, etc. in the environment surrounding the first energy storage module. The operating conditions may also include active cooling and / or heating rates. The battery state may be another operating condition and may refer to the charge state of each energy storage device of the module, the current charge transfer operation of the module (such as, providing current or receiving current), and / or the current load or current demand on the module. The load on the energy storage module may represent the rate at which the energy storage module provides current to the traction motor or auxiliary motor (e.g., ampere-hour rate). Another operating condition may be the vehicle state (e.g., locomotive state for rail vehicle applications), which may refer to whether the vehicle on which the deviation detection system may be set may be braking, coasting, accelerating, stationary, turned off, etc.

[0042] The characteristics 310 of the energy storage module refer to inherent physics-based characteristics, such as the chemistry of the energy storage device (e.g., battery chemistry), the type and / or model of the energy storage device, the modeled thermal characteristics of the energy storage device, etc. The modeled thermal characteristics may refer to the amount of heat generated during operation.

[0043] The historical information 312 about the energy storage device may refer to the age of the energy storage device 108 that defines the energy storage device, and / or the state of health of the energy storage device. For example, the resistance of the energy storage device may be expected to gradually increase over its operating life. The state of health may refer to the condition of the energy storage device, which may take into account the operating life, the charge capacity of the energy storage device, the current state of charge of the energy storage device, etc. For example, a fully charged energy storage device is more likely to experience thermal runaway than a partially depleted energy storage device due to the greater amount of stored energy.

[0044] The historical information 314 about other energy storage modules can refer to observations and trends based on the performance of the energy storage modules, whether the energy storage modules are in the same energy storage system or in a different energy storage system than the first energy storage module. The other energy storage modules can be similar to the first energy storage module, such as including the same number and / or type of energy storage devices as the first module. As an example, the information can include observed thermal heating rates of the other energy storage modules in response to specific stimuli such as environmental conditions and loads applied to the other energy storage modules.

[0045] The control circuitry may utilize some or all of the input data 304, 306, 308, 310, 312, 314 to determine a reference value and / or change in a particular parameter. For example, the control circuitry may insert the operating conditions, inherent characteristics, and historical information about the energy storage module into a physics-based computational model. The physics-based computational model may be a computer program that generates a reference value and / or reference change in a particular parameter based on an algorithm that includes multiple calculations using the input data as variables. The physics-based model may also utilize additional information, such as local sensor measurements, sensor measurements from other energy storage modules, and / or historical information about other energy storage modules.

[0046] As described above, reference values ​​and / or changes for particular parameters may be derived from one or more functions and other known relationships based on one or more measurement results, such that the reference values ​​and / or changes may not only be parameters directly measured by the sensor.

[0047] Non-limiting examples of derived specific parameters include power, RMS current, harmonic spectrum, bias, resistance, statistical metrics (e.g., mean, median, mode, standard deviation, etc.), and the like. In a non-limiting example, the specific parameter may represent a statistical metric, and the control circuitry may compile all sensor measurements representing the given parameter generated by sensors incorporated into the energy storage system. Thus, for a temperature parameter, the control circuitry may compile sensor measurements generated by temperature sensors associated with all energy storage modules in the system. Alternatively, the control circuitry may narrow the scope of the compiled sensor measurements to sensor measurements generated by specific sensors associated with the same energy storage module or the same energy storage device. The control circuitry may determine a reference value and / or variance by performing statistical calculations on the compiled sensor measurements. For example, the control circuitry may calculate a reference value for temperature as the average (e.g., mean), median, or other specified value of the compiled temperature measurements. Furthermore, the control circuitry may arrange the sensor measurements in a distribution from low to high, and may determine a reference variation (or range) for a particular parameter by selecting measurements at specified percentiles of the distribution as upper and lower limits, with the upper and lower limits defining the boundaries of the reference variation. For example, if the specified percentiles may be 40% and 60%, the control circuitry may designate the sensor measurement at the 40th percentile of the distribution as the lower limit, and the sensor measurement at the 60th percentile of the distribution as the upper limit. In other embodiments, the control circuitry may determine the reference value and / or variation for a particular parameter through other processes.

[0048] The control circuitry may determine a reference value and / or variation for each of a plurality of different specific parameters of the energy storage module. For example, the control circuitry may determine a reference value and / or variation for temperature, a different reference value and / or variation for power, a different reference value and / or variation for RMS current, and / or the like.

[0049] At 315, a monitored value and / or change in a particular parameter may be determined. The monitored value and / or change may be based on local sensor measurements (at 304) of sensors associated with the particular energy storage module being analyzed. As described above, the particular parameter may represent a measured parameter such as temperature, current, voltage, etc., or a derived parameter such as power, average temperature, resistance, RMS current, etc. External sources (such as operating conditions, historical information, and sensor measurements from other energy storage modules) may not be used to determine the monitored value and / or change.

[0050] At 316, the control circuit compares the monitored value and / or change of the particular parameter with a reference value and / or change of the particular parameter to determine the degree and / or rate of deviation. The comparison can be performed for the purpose of detecting outlier sensor measurements that may indicate a component failure, such as a battery cell that has caught fire or is experiencing thermal runaway. Based on the actual measurements generated by the sensors, the monitored behavior of the energy storage module can be compared with the expected behavior.

[0051] This comparison can include a specified tolerance margin designed to accommodate differences due to sensor accuracy, differences due to varying sensor ages, gradients due to differences in packaging conditions and / or energy storage device placement, differences in the quality of cell-to-cell connections, and so on. The specified tolerance margin can be a fixed, preset range of a reference value (such as + / - 2%, 5%, or 10%), or a preset number of degrees of standard deviation from a reference value (e.g., within a standard deviation of 2 degrees). For temperature parameters, the specified tolerance margin can be set as a percentage or as a number in degrees, such as + / - 2 degrees, 4 degrees, 6 degrees, or 10 degrees relative to a reference temperature value. Alternatively, the specified tolerance margin can be dynamic and a function of other conditions (such as current, age, etc.). For example, the tolerance margin can be changed and adjusted based on the amount of current passing through the energy storage module. When current is low, the specified tolerance margin may be narrower than when current is high due to variables that may be affected by current (such as resistance). In another example, as the energy storage module ages, the specified tolerance margin may increase over time since the energy storage device may be expected to perform closer to what is expected during earlier stages of life than later stages of life.

[0052] A specified tolerance can also optionally be applied to a reference variation. For example, if the reference variation between temperature measurements is 10 degrees, a specified tolerance can extend the acceptable variation range to 11 or 12 degrees. Thus, if the measured difference between two temperature measurements is 10.5 degrees, the control circuitry can determine that this difference does not violate the reference variation. While the comparison described may be based on individual sensor values ​​or individual transformed values, it will be appreciated that two-dimensional or three-dimensional vector comparisons (e.g., lines or planes) are also contemplated.

[0053] At 318, the control circuit detects a deviation condition in response to detecting one or more outliers or deviating monitored values ​​and / or changes. The deviating monitored values ​​and / or changes represent monitored values ​​and / or changes that deviate from a reference value and / or change by more than a specified tolerance (based on local sensor measurements 304 generated by one or more sensors associated with the first energy storage module). It will be appreciated that these deviating monitored values ​​and / or changes do not include sensor data that was previously filtered out and / or replaced.

[0054] After a deviation condition may be detected, the control circuitry initiates one or more response actions 320. Response actions 320 may include, at least temporarily, changing the operating conditions of the energy storage module, such as preventing current flow to and from the energy storage module, isolating the energy storage module from other modules (e.g., a second module). For example, if an energy storage module may be on fire or has one or more energy storage devices experiencing thermal runaway, isolating the energy storage module may help prevent damage, such as thermal runaway, from spreading to other energy storage modules. Response actions may also include adjusting a non-zero rate of current flow to the module, inducing a specified load applied to the module, adjusting the ambient temperature around the module, adjusting the air flow rate around the module, initiating active cooling, initiating fire suppression, marking the module for repair and / or replacement, de-rating or otherwise changing the operation of a vehicle on which the energy storage system may be installed, notifying a human operator, and the like. The control circuitry may automatically generate a control signal upon detecting a deviation condition to initiate one or more of these response actions.

[0055] Upon detecting a deviation condition, the control circuitry may automatically initiate one or more temporary actions based on a worst-case scenario. In one embodiment, the worst-case scenario represents thermal runaway and / or fire to the energy storage device, which has the potential to spread to other devices in the same or different modules, thereby causing significant permanent damage and risk of injury. Thus, the control circuitry may initiate one or more temporary actions associated with thermal runaway and / or fire upon detecting a deviation condition, even if the actual cause may be less severe. The temporary actions may include increasing active cooling, initiating fire suppression, electrically isolating the energy storage module from other modules, reducing the load on the energy storage system, reducing the vehicle's tractive effort rating, notifying the operator, and the like.

[0056] In one embodiment, the control circuitry may also determine which of the sensors generated the deviating monitoring values ​​and / or sensors on which the change may be based, and may mark these sensors. Furthermore, the control circuitry may estimate the cause of the deviating condition based at least in part on the sensor measurements generated by these specific sensors. As used herein, the cause of the deviating condition may include the identification of a component and / or the condition of the component. For example, the control circuitry may distinguish the cause as one or more of a bad weld, a failed energy storage device, a failed sensor, a broken tab connecting two energy storage devices, and so on. After estimating the cause, the control circuitry may customize a response action based on the specific estimated cause. For example, if the estimated cause may be a failed sensor, the control circuitry may mark the sensor for repair or replacement, notify an operator, replace the sensor, and so on. Furthermore, because a failed sensor may not be a worst-case scenario, the control circuitry may halt execution of temporary remedial actions based on the worst-case scenario. For example, the control circuitry may increase the load on the energy storage system, allow for increased vehicle performance, slow or halt active cooling, halt fire suppression, and so on. In another example, if the estimated cause may be a failed energy storage device, then in order to prevent or stop the spread of secondary damage caused by fire or thermal runaway, the control circuit can expand the execution of temporary remedial actions based on the worst-case scenario, such as maintaining electrical isolation of the energy storage device and / or module to be addressed, maintaining active cooling, maintaining fire extinguishing, etc.

[0057] Figure 4 It may be a diagram of a temperature sensor associated with an energy storage module according to an embodiment (e.g., Figure 1 A graph 400 of sensor measurements generated by the temperature sensors 114 shown in FIG. 1 is provided to facilitate understanding. The graph includes a vertical axis 402 representing temperature in degrees Celsius and a horizontal axis 404 representing time in seconds. The graph includes six plot lines 406A-F representing example sensor measurements generated by each of the six temperature sensors associated with the energy storage module. The energy storage module may be Figure 1. A first plotted line 406A represents a temperature measurement generated by one of the temperature sensors associated with the first energy storage device of the module, and a second plotted line 406B represents a temperature measurement generated by another temperature sensor associated with the first energy storage device. A third plotted line 406C represents a temperature measurement generated by one of the temperature sensors associated with the second energy storage device, and a fourth plotted line 406D represents a temperature measurement generated by another temperature sensor associated with the second energy storage device. Fifth and sixth plotted lines 406E, 406F represent measurements generated by two temperature sensors associated with the third energy storage device.

[0058] Graph 400 includes a plot line 408 representing a reference (or expected) temperature (e.g., temperature value) over time. The reference temperature line may be bounded above and below by a specified tolerance margin 410. Specified tolerance margin 410 extends above the reference temperature line to an upper line 412 and below the reference temperature line to a lower line 414. In the illustrated embodiment, the specified tolerance margin may be + / - 3 degrees relative to the reference temperature line. For example, when the reference temperature line may be at 22°C at approximately 400 seconds, the upper line may be at 25°C, and the lower line may be at 19°C. Although the specified tolerance margins may be static in the illustrated graph, as described above, tolerance margins may be dynamic and may change over time based on operating conditions, age, etc. Furthermore, although tolerance margins may be represented in the graph by two-dimensional plot lines, tolerance margins may be represented in three dimensions along a plane, such as if the tolerance margins may be a function of multiple parameters.

[0059] As shown in the graph, at 100 seconds, all six temperature measurements 406A-F are within a specified tolerance of the reference temperature value. At 500 seconds, something causes third plot line 406C to indicate a fairly consistent temperature increase, which differs from the other plot lines and the reference temperature line. Third plot line 406C crosses absolute threshold 416 at a specified temperature of 32°C at approximately 900 seconds. Conventional battery monitoring systems can detect the deviation at time 900 seconds in response to the third plot line crossing the threshold. The deviation detection system disclosed herein can provide early detection of anomalies. For example, the control circuit can detect a deviation condition in response to the third plot line deviating from the reference temperature line by more than a specified tolerance (which occurs at or around 600 seconds when the third plot line crosses the upper line). Thus, the control circuitry can detect a deviation condition and initiate responsive action several minutes before a deviating temperature measurement exceeds a specified threshold, which can prevent or reduce the spread of damage compared to waiting until the threshold is likely to be crossed before taking action. Furthermore, by determining that the rate of change of the represented temperature differs from the rate of change of the reference value by more than a specified threshold tolerance, the deviation detection system described herein can detect the deviation even before the third plot line crosses the upper line. For example, between times 500 and 600 seconds, the slope of the plot line may deviate from the slope of the reference temperature line by more than a specified threshold tolerance and may be detected by the control circuitry as a deviation condition.

[0060] Graph 400 also indicates that at or around 650 seconds, the slope of first plot line 406A changes and deviates from the slope of the reference temperature line. For example, the first plot line indicates a faster temperature increase than the reference temperature line. Although the first plot line does not deviate from the reference temperature line by more than a specified tolerance, the control circuitry can detect a deviation condition based on the deviation in slope between the first plot line and the reference temperature line. Additionally or alternatively, the control circuitry can detect a deviation condition based on a change between the first plot line and one or more of the other plot lines -F that exceeds a reference change. For example, the control circuitry can determine a reference change of 3°C (incorporating any specified tolerance) between sensor measurements of temperature sensors associated with the same energy storage device. First and second plot lines 406A, 406B represent sensor measurements of two temperature sensors associated with the same energy storage device. The graph indicates that the first plot line differs from the second plot line by more than 3°C at some time between 800 and 900 seconds. Thus, in response to a change between the first plot line and the second plot line exceeding a reference change, the control circuitry may detect a deviation condition (even if the first plot line remains within a specified tolerance of the reference temperature line).

[0061] This graph indicates that a deviation condition can be detected based on various characteristics of sensor measurements over time, such as value, change in value (e.g., slope), rate of change in value, change in sensor measurements, and so on. A deviation condition can be detected independently of any of the sensor measurements exceeding a preset threshold (such as the thresholds shown in the graph). For example, even if, in an alternative embodiment, the third plot line flattens after exceeding the upper line, such that the line never exceeds the threshold, the deviation detection system may be able to detect a deviation condition based on the absolute value of the temperature, the slope of the plot line, changes between the plot line and other monitored temperature plot lines, and so on. The deviation detection system can also be configured to detect noisy and / or damaged sensors based on the measurement results. For example, a plot line generated based on measurements from a noisy sensor may fluctuate more than a plot line based on measurements from a more accurate sensor. Furthermore, a damaged sensor may provide consistent, unchanging measurements, which would be plotted as a horizontal line in the graph. In response to detecting noisy and / or damaged sensors, the control unit can ignore and / or replace these sensors.

[0062] Although the graph plots temperature measurements from a temperature sensor, it will be appreciated that deviation conditions may be detected based on other types of parameters in addition to or in lieu of temperature, such as current, voltage, state of charge, charge capacity, pressure, coolant flow rate, and any derived or transformed measurement (e.g., power, RMS current, resistance, etc.).

[0063] Figure 5 500 may be a flow chart of a method 500 for detecting and responding to an offset condition in an energy storage system according to an embodiment. The method may be performed in whole or in part by Figure 1 The method may be executed by the control circuit 104 shown in FIG. 1 , which includes one or more processors thereof. Optionally, the method may include additional steps, fewer steps, and / or different steps than the flowchart shown.

[0064] Additional references Figures 1 to 4 The method begins at 502, where sensor measurements representing parameters of an energy storage module may be obtained. The sensor measurements may be generated by a first set of sensors associated with the energy storage module. The energy storage module includes one or more energy storage devices, such as, but not limited to, battery cells. The sensor measurements may be obtained directly from the sensors or by accessing sensor data from an electronic storage device, such as a memory, a server, or the like.

[0065] At 504, a reference value and / or a reference change in a particular parameter of the parameter may be determined. For example, the particular parameter may be temperature, current, voltage, resistance, state of charge, capacity, etc. The reference value and / or change may be determined based on sensor measurements generated by a first set of sensors associated with the energy storage module, sensor measurements generated by a second set of sensors associated with at least a second, different energy storage module 106, inherent characteristics of the energy storage module (and its devices), operating conditions of the energy storage module, and / or historical information about the energy storage module or about other energy storage modules.

[0066] At 506, a monitored value and / or change representing a specific parameter may be compared to a reference value and / or reference change for the specific parameter, where the monitored value and / or change may be based on sensor measurements obtained from sensors in a first group associated with the energy storage module. The monitored value and / or change based on the sensor measurements of each associated sensor in the first group may be individually compared to the reference value and / or change. For example, if the specific parameter may be voltage, the voltage measurement of each voltage sensor in the first group may be compared to the reference value and / or change. In another example where the specific parameter may be power, the voltage and current measurements of the voltage and current sensors may be used to derive a power value and / or change, which may each be compared to a reference power value and / or change.

[0067] At 508, a determination may be made as to whether all monitored values ​​and / or changes representing a particular parameter are likely to be within a specified tolerance of a reference value and / or change of the particular parameter. If none of the monitored values ​​and / or changes deviate from the reference value and / or change by more than the specified tolerance, the answer may be "yes," and the method returns to 502. On the other hand, if at least one of the monitored values ​​and / or changes deviates from the reference value and / or change by more than the tolerance, the answer may be "no," and the method continues to 510.

[0068] At 510, in response to determining that one or more of the monitored values ​​and / or changes may be deviated monitored values ​​and / or changes that deviate from a reference value and / or change by more than a tolerance, a deviation condition may be detected. The deviation condition indicates that a potential fault or malfunction may exist in one or more components (such as an energy storage device, a sensor, a weld, a tab connecting the energy storage device, etc.). At 512, one or more sensors in a first group that generated at least some of the sensor measurements on which the deviated monitored values ​​and / or changes may be based may be identified. For example, the sensor measurements may have a data tag indicating the source of the measurement (e.g., which sensors generated the measurement). The first sensor may be identified based on the data tag associated with the deviated monitored value and / or change. Multiple sensors may be identified if the deviated monitored value and / or change may be based on measurements generated by different sensors.

[0069] At 514, a cause of the deviation condition can be estimated. The cause of the deviation condition can be estimated based, at least in part, on sensor measurements generated by the first sensor and the other identified sensors. For example, the cause of the deviation condition can be estimated by analyzing the sensor measurements generated by the first sensor using: (i) sensor measurements representing the same parameter generated by other sensors in the first group; (ii) sensor measurements representing another parameter generated by other sensors in the first group; and / or (iii) sensor measurements (representing the same parameter and / or different parameters) generated by different groups of sensors associated with different energy storage modules. For example, if temperature can be a specific parameter, outlier temperature measurements generated by one or more temperature sensors in the first group can be analyzed using: non-outlier temperature measurements generated by other temperature sensors in the first group; voltage measurements generated by voltage sensors in the first group; current measurements generated by current sensors in the first group; and / or temperature, voltage, and current measurements generated by different sensors in the second group. The cause of the deviation condition can be estimated based on observed trends and relationships in the sensor measurements that can be analyzed, as described in more detail herein.

[0070] Optionally, the cause of the deviation condition can be estimated by taking a temporary action at 516 and observing the impact of the temporary action. The temporary action can include changing at least one operating condition of the energy storage module for at least a specified time period. The control circuit can initiate the temporary action by generating a control signal to change the operating condition(s). The control signal can be transmitted to the intended recipient by the communication device. For example, the temporary action can include electrically isolating the energy storage module from other modules in the energy storage system by preventing the flow of current to and from the energy storage module. The energy storage module can be isolated by disconnecting an electrical switch to break the conductive path between the module and adjacent modules. If it turns out that one or more energy storage devices may be on fire or experiencing thermal runaway, isolating the module may help prevent the spread of damage. Once the energy storage module can be disconnected from the other modules, it can be expected that the temperature of one or more energy storage devices of the module will move toward the ambient temperature.

[0071] Another temporary action could be to start, shut down, and / or adjust a cooling or heating medium (such as an air conditioner) to change the ambient temperature. If the energy storage device is likely to be under no load, the device should approach the new ambient temperature over time. Yet another optional temporary action could be to adjust the air flow rate around the module, such as by turning on, shutting down, or modifying the activity of a fan or pump. When the energy storage device is likely to be under load, shutting down the fan and / or pump should result in an increase in the device's temperature, while shutting down the fan and / or pump should result in a decrease in temperature (if the ambient temperature is likely to be lower than the device's temperature).

[0072] Still other temporary actions may include sensing a specified load on the energy storage module and / or adjusting a non-zero rate of current transfer into or out of the energy storage module. The temporary action may be taken for a specified amount of time, which may be preset, such as five minutes, thirty minutes, or the like. Optionally, the specified amount of time may be extended until the cause of the deviation condition can be assessed. For example, if the cause can be assessed to be a bad sensor, the temporary action of providing active cooling may be discontinued because there is little risk of a fire or overheating of the energy storage device due to the bad sensor.

[0073] At 518, sensor measurements generated by the identified sensors (which produced outlier monitored values ​​and / or changes) can be monitored after the temporary action is taken. These subsequent post-action measurements of these sensors can be compared with pre-action sensor measurements generated by these sensors before the temporary action was taken to determine the impact of the temporary action on the sensor measurements. For example, if the post-action measurements may still be consistent with the pre-action measurements even though the change in operating conditions constituting the temporary action would have been expected to alter the measurements, the cause of the deviating condition may be a malfunctioning sensor. Thus, if the temperature measurements of a temperature sensor do not change over time when there is active cooling and / or isolation of the module that would be expected to cool the module, the control circuitry may estimate that the temperature sensor may be malfunctioning.

[0074] In another example, the post-action measurement of the identified sensor can be compared with the measurement results of other sensors that can be assumed to be operating normally. If the post-action measurement results are consistent with the measurement results of the other sensors, the identified sensor can be estimated to be operating normally, indicating that the energy storage device or associated components may be malfunctioning, damaged, or faulty. Additional scenarios for estimating the cause of the deviation condition can be described below.

[0075] At 520, after estimating the cause of the deviation condition, remedial action can be initiated, which can be based on the estimated cause. For example, if it can be estimated that a sensor may be defective, the control circuitry can generate a control signal to mark the sensor for replacement, to replace the sensor when performing subsequent monitoring, to notify an operator that the sensor may be malfunctioning (e.g., and that the energy storage device may be operating normally), to cease temporary actions taken to limit heat-related damage, such as actively cooling and / or isolating the energy storage module, etc. In another example, if it can be estimated that an energy storage device of a module may be malfunctioning, the control circuitry can generate a control signal to extend execution of temporary actions taken to limit heat-related damage, mark the module for replacement of one or more of its energy storage devices, notify an operator, derate the performance of a vehicle incorporating the energy storage system, initiate fire suppression, etc.

[0076] Various non-limiting example scenarios may be provided below that indicate how the control circuit may be able to estimate the cause of a deviation condition based on analyzing sensor measurements.The following examples relate to battery cells, but the embodiments described herein may not be limited to battery cells.

[0077] In the first temperature example, if only one battery cell temperature sensor is consistently getting hotter than the other temperature sensors for that battery cell, the control circuitry may estimate that the cause of the deviation is likely a bad weld. In response, depending on the severity of the bad weld, the control circuitry may ignore the bad weld, notify an operator, continue operation, derate the performance of the energy storage system, and / or shut down the energy storage system.

[0078] In the second temperature example, if the control circuit detects that a battery temperature sensor may be outside the upper range limit, while an adjacent sensor may be within the normal range, the control circuit may isolate the module to remove the load from the module. If the temperature measurement generated by a sensor remains outside the upper range limit after isolating the module, the sensor may be malfunctioning. In response, the control circuit may ignore the measurement result of the sensor or replace the sensor with a later monitoring algorithm.

[0079] In a third temperature example, if an unexpected increase occurs in two or more temperature sensors and / or if a temperature spike occurs in the vent duct, the control circuitry may estimate that one or more of the battery cells may be heating up. Depending on the severity, the control circuitry may ignore the temperature increase, alert the operator and continue operation, derate the energy storage system, shut down the energy storage system, flag one or more batteries for replacement, initiate fire suppression, and / or initiate active cooling.

[0080] In the fourth temperature example, if the temperature measurements generated by the temperature sensor may be trending away from a set ambient temperature within the insulated chamber (e.g., based on the cooling / heating medium), the cooling / heating medium may be malfunctioning. In response, the control circuitry may notify the operator that the cooling / heating medium may not be functioning properly and may shut down the cooling / heating medium and prevent further use of the cooling / heating medium.

[0081] In the fifth temperature example, if the average module temperature and battery pack temperature have reached consistent thresholds over time (e.g., based on historical records), the control circuitry can estimate that the energy storage module may be at the end of its life. In response, the control circuitry can schedule the module for replacement and prevent it from further use.

[0082] In a first voltage example, if the monitored voltage of one battery cell increases or decreases faster than the other batteries under load based on voltage measurements generated by the voltage sensor, the control circuitry may estimate that the battery tab of the battery cell may be damaged or compromised. In response, the control circuitry may disregard the damaged battery tab, derate the energy storage module, and / or shut down the energy storage module.

[0083] In the second voltage example, a malfunctioning sensor can be detected by comparing the voltage measurements of a module with the voltage measurements of the module's individual cells and identifying differences or deviations. In response, the measurements of the malfunctioning sensor may be ignored or replaced with additional monitoring algorithms.

[0084] In the third voltage example, the control circuit can detect a damaged measurement card by comparing the voltage measurement of a module or module string with the sum of the voltages of its cells and identifying the difference. In response, one or more of the modules can be marked for replacement.

[0085] In the fourth voltage example, if the maximum to minimum range of cell voltages for a given module or string of modules may be large, an imbalance may exist. In response, the control circuitry may derate the performance of the energy storage system and / or perform cell balancing.

[0086] In the fifth voltage example, over-discharge can be detected by tracking the slope of voltage measurements while the module is likely under no load. Before shutting down the energy storage system, the voltage, temperature, and time can be recorded. When the energy storage system is back online, the voltage, temperature, and time of the same module can be compared to the recorded values ​​to determine if over-discharge is likely. If so, the module can be flagged for replacement.

[0087] In a sixth voltage example, if adjacent cells or modules have different voltages (e.g., one increasing while the other decreasing) during a common time period while the energy storage system may be offline, the control circuitry may detect a short circuit. In response, the control circuitry may notify an operator, mechanically disconnect the cell or module, and / or flag the cell or module for replacement.

[0088] In the seventh voltage example, a faulty fuse, connection device, current sensor, or other component may be detected. If the current measurement generated by the current sensor is relatively high and the monitored voltage of the module or module string suddenly drops to zero, the control circuit may detect a faulty fuse. If the voltage measurement does not increase or decrease when expected, a faulty connection device may be detected. If the voltage measurement increases and / or decreases when expected but the current sensor reads zero, a faulty current sensor may be detected. In addition, if the magnitude of the current measurement is relatively high while the voltage measurement is stable, a faulty current sensor may be detected. In response to detecting any of these faulty components, the control circuit can isolate the particular module, mark the module (or some of its internal components) for repair, and / or continue operation if available.

[0089] In the eighth voltage example, impending thermal runaway can be detected in response to a hump in the voltage measurement over time (e.g., an increase followed by an immediate decrease). In response, the control circuitry can disconnect the module, notify an operator, activate fire suppression or active cooling, and / or flag the module for replacement.

[0090] In a ninth voltage example, if the voltage measurements indicate that the battery is failing to hold a charge and / or that voltage depletion may be rapid during discharge, the battery may be vented. In response, the control circuitry may notify an operator, disconnect or isolate the module, and / or tag the module for replacement.

[0091] In the tenth voltage example, if a rapid voltage drop is detected while charging, the control circuit may detect an internal short circuit. In response, the control circuit may notify the operator, disconnect or isolate the module, and / or mark the module for replacement.

[0092] In an eleventh voltage example, a miswiring may be detected in response to a deviation in a reference voltage measurement with respect to a wire chassis having partial connections to a module. In response, the wiring may be flagged for repair, operation may continue if applicable, and / or the module or module string may be isolated.

[0093] In a twelfth voltage example, a ground fault can be detected in response to a shift in voltage measurements associated with a module string. The sum of the voltage measurements across the module can be determined to verify the shift. In response, the control circuitry can isolate the module string, continue operation, notify an operator, and / or schedule maintenance.

[0094] Technical effects of one or more embodiments of the deviation detection systems and methods described herein may include early detection of malfunctioning and faulty components, enabling early remedial action to prevent and / or reduce damage caused by the malfunctions and faults. For example, early detection of a fire and / or thermal runaway in an energy storage device may allow for early action to prevent the fire and thermal runaway from spreading to other energy storage devices, thereby reducing hazards and preserving and extending the life of the operating energy storage devices. Another technical effect of the deviation detection systems and methods may include the ability to provide automated, cause-specific responses to detected anomalies. For example, by estimating the cause of an anomaly based on analysis of sensor measurements, control circuitry can initiate actions tailored to the estimated cause, increasing efficiency and providing better support to the energy storage system compared to known monitoring systems that provide the same response action for every detected deviation. For example, if the control circuitry estimates that the cause of the deviation is likely to be trivial, such as a damaged sensor, the control circuitry may allow the energy storage system to continue operating, thereby providing beneficial operating output, rather than automatically shutting down the energy storage system to address a worst-case scenario of fire and / or thermal runaway.

[0095] In one embodiment, a system includes a first set of sensors and a control circuit including one or more processors. The first set of sensors is associated with an energy storage module including one or more energy storage devices. The sensors in the first set are configured to generate sensor measurements representing one or more parameters of the energy storage module. The control circuit is configured to receive the sensor measurements generated by the sensors and determine a reference value and / or reference change for a specific parameter related to the energy storage module based at least in part on the sensor measurements. The control circuit is configured to compare the monitored value and / or monitored change for the specific parameter with a reference value and / or reference change for the specific parameter based on the sensor measurements generated by the sensors in the first set, and detect deviations greater than a specified tolerance.

[0096] Optionally, the control circuit is configured to determine a reference value and / or a reference change for a particular parameter based on sensor measurements generated by a first set of sensors associated with the energy storage module and one or more of: (i) sensor measurements generated by a second set of sensors associated with a different second energy storage module; (ii) inherent characteristics of the energy storage module; (iii) operating conditions of the energy storage module; or (iv) historical information about the energy storage module or about other energy storage modules.

[0097] Optionally, in response to detecting a deviation greater than a specified tolerance, the control circuitry is configured to: identify a particular sensor in the first group that generated a sensor measurement on which one or more of the deviated monitoring value and / or monitoring change are based, and to: estimate a cause of the deviation by comparing the sensor measurement generated by the particular sensor with sensor measurements generated by other sensors in the first group or sensor measurements generated by other sensors in the second group associated with a different second energy storage module.

[0098] Optionally, in response to detecting a deviation greater than a specified tolerance, the control circuit is configured to generate a control signal configured to change one or more operating conditions of the energy storage module. Optionally, the control signal is configured to change the one or more operating conditions of the energy storage module by one or more of: (i) preventing current delivery from the energy storage module; (ii) adjusting a non-zero rate of current delivery from the energy storage module; (iii) adjusting an ambient temperature around the energy storage module; (iv) adjusting a rate of temperature regulation around the energy storage module; (v) sensing a specified load on the energy storage module; (vi) initiating active cooling; (vii) initiating fire suppression; or (viii) flagging the energy storage module for repair.

[0099] Optionally, the control circuitry is configured to: identify a particular sensor in the first group that generated the deviated monitoring value and / or the sensor measurement on which one or more of the monitoring changes are based. The control circuitry is configured to: monitor additional sensor measurements generated by the particular sensor during the determined time period after changing one or more operating conditions of the energy storage module. The control circuitry is configured to: estimate a cause of the deviation based at least in part on the additional sensor measurements generated by the particular sensor during the determined time period.

[0100] Optionally, the control circuit is further configured to detect a deviation greater than a specified tolerance margin independently of any of the sensor measurements exceeding a preset threshold.

[0101] Optionally, one or more energy storage devices of the energy storage module are batteries.The energy storage module represents one or more of a single battery cell, an assembly of multiple battery cells connected in series, or an assembly of multiple battery cells connected in parallel.

[0102] Optionally, the specific parameter is one of temperature, voltage, current, power, state of charge, charge capacity, pressure, coolant flow rate, or resistance.

[0103] Optionally, the control circuit is configured to determine a reference value and / or reference change for a particular parameter based on a physics-based model that incorporates inherent characteristics of the energy storage module, operating conditions of the energy storage module, and historical information about the energy storage module.

[0104] Optionally, the control circuit is configured to determine the reference value and / or reference change of the particular parameter at least in part by compiling sensor measurements generated by sensors in the first group.

[0105] Optionally, the control circuitry and the first set of sensors are provided on a vehicle that is at least partially propelled by the energy storage module.

[0106] In one embodiment, a method includes obtaining sensor measurements generated by a first group of sensors associated with an energy storage module. The energy storage module includes one or more energy storage devices. The sensor measurements represent one or more parameters of the energy storage module. The method includes comparing a monitored value and / or monitored change of a specific parameter associated with the energy storage module with a reference value and / or reference change of the specific parameter. Both the monitored value and / or monitored change and the reference value and / or reference change are based at least in part on the sensor measurements generated by the first group of sensors. The method includes detecting a deviation condition in response to one or more of the monitored values ​​and / or monitored changes deviating from the reference value and / or reference change by more than a specified tolerance. The method also includes identifying a first sensor in the first group that generated the sensor measurement on which one or more of the deviated monitored values ​​and / or monitored changes are based; and estimating a cause of the deviation condition based at least in part on the sensor measurements generated by the first sensor.

[0107] Optionally, in response to detecting the deviation condition, the method further comprises generating a control signal to change one or more operating conditions of the energy storage module. Optionally, a cause of the deviation condition is estimated at least in part by comparing sensor measurements generated by the first sensor before changing one or more operating parameters of the energy storage module with sensor measurements generated by the first sensor after changing the one or more operating parameters.

[0108] Optionally, the control signal is configured to change one or more operating conditions by one or more of: (i) adjusting the ambient temperature surrounding the energy storage module; (ii) adjusting the rate of temperature regulation surrounding the energy storage module; (iii) sensing a specified load on the energy storage module; (iv) replacing a first sensor; (v) preventing current transfer operation of the energy storage module; (vi) adjusting a non-zero rate of current transfer of the energy storage module; (vii) initiating active cooling; (viii) initiating fire suppression; or (ix) marking the energy storage module for repair.

[0109] Optionally, the method further includes determining a reference value and / or a reference change for a specific parameter based on sensor measurements generated by a first set of sensors associated with the energy storage module and one or more of: (i) sensor measurements generated by a second set of sensors associated with a different second energy storage module; (ii) inherent characteristics of the energy storage module; (iii) operating conditions of the energy storage module; or (iv) historical information about the energy storage module or about other energy storage modules.

[0110] Optionally, the cause of the deviation condition is estimated by comparing the sensor measurements generated by the first sensor with one or more of: (i) sensor measurements generated by other sensors in the first group; or (ii) sensor measurements generated by a second group of sensors associated with a different second energy storage module.

[0111] Optionally, the specific parameter is one of temperature, voltage, current, power, state of charge, charge capacity, pressure, coolant flow rate, or resistance.

[0112] In one embodiment, a system includes a control circuit having one or more processors. The control circuit is configured to obtain sensor measurements generated by a first group of sensors associated with an energy storage module, the energy storage module including one or more energy storage devices. The sensor measurements represent one or more parameters of the energy storage module. The control circuit is configured to compare the sensor measurements representing a particular parameter of the one or more parameters with a reference value for the particular parameter and / or a reference change in the particular parameter. In response to detecting that one or more of the sensor measurements deviate from the reference value and / or the reference change by more than a specified tolerance, the control circuit is configured to identify a first sensor in the first group that generated at least some of the one or more deviated sensor measurements; estimate a cause of the deviation based at least in part on the sensor measurements generated by the first sensor; and generate a control signal to initiate one or more remedial actions based on the estimated cause.

[0113] The above description is intended to be illustrative and not limiting. For example, the embodiments described above (and / or aspects thereof) may be used in combination with each other. Additionally, many modifications may be made to the teachings of the present invention to adapt to a particular situation or material without departing from the scope of the present invention. While the dimensions and types of materials described herein define the parameters of the present invention, they are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those of ordinary skill in the art upon reviewing the above description. Therefore, the scope of the present invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0114] This written description uses examples to disclose several embodiments of the inventive subject matter and also to enable one of ordinary skill in the art to practice the embodiments of the inventive subject matter, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the inventive subject matter is defined by the claims, and may include other examples that occur to one of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

[0115] The foregoing description of certain embodiments of the inventive subject matter will be understood when read in conjunction with the accompanying drawings. To the extent that the drawings illustrate diagrams of functional blocks of various embodiments, the functional blocks do not necessarily indicate the division between hardware circuits. Thus, for example, one or more of the functional blocks (e.g., a processor or memory) may be implemented in a single piece of hardware (e.g., a general-purpose signal processor, a microcontroller, random access memory, a hard disk, etc.). Similarly, a program may be a stand-alone program, incorporated as a subroutine in an operating system, a function in an installed software package, and so on. The various embodiments are not limited to the arrangements and instrumentality shown in the drawings.

[0116] As used herein, an element or step recited in the singular and beginning with the word "a" or "an" should be understood as not excluding a plurality of said elements or steps, unless such exclusion is explicitly stated. In addition, reference to "one embodiment" of the subject matter of the present invention is not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, an embodiment that "comprises," "includes," or "has" an element or multiple elements having a particular property may include additional such elements that do not have that property. In the appended claims, the terms "comprise" and "in which" are used as the plain English equivalents of the corresponding terms "comprising" and "wherein." In addition, in the following claims, the terms "first," "second," and "third," etc. are used merely as labels and are not intended to impose numerical requirements on their objects. Furthermore, the following claim limitations are not written in a “means-plus-function” format and are not intended to be interpreted based on 35 USC §112(f) unless and until such claim limitation expressly utilizes the term “means for…” followed by a statement of function without further structure.

Claims

1. A system comprising: a first set of sensors associated with an energy storage module comprising one or more energy storage devices, the first set of sensors configured to generate sensor measurements representative of one or more parameters of the energy storage module; as well as a control circuit comprising one or more processors, the control circuit being configured to: receive sensor measurements generated by the first set of sensors, and determine one or more of a reference value or a reference change over time for a particular one of the one or more parameters based at least in part on the sensor measurements; and wherein the control circuit is configured to compare one or more of the monitored values ​​or monitored changes of the particular parameter based on sensor measurements generated by the first set of sensors with a reference value or reference change of the particular parameter, and detect a deviation condition in response to one or more of: (i) a rate of change of the monitored value differing from a rate of change of the reference value by more than a specified tolerance margin for rate of change, or (ii) a monitored change between two monitored values ​​of the particular parameter exceeding a reference change by more than a specified tolerance margin for change, wherein the two monitored values ​​defining the monitored change are based on sensor measurements generated by two different sensors of the first set of sensors, wherein the control circuit is configured to determine a reference value or a reference change of the specific parameter based on sensor measurements generated by a first set of sensors associated with the energy storage module and an operating condition of the energy storage module, and wherein the specified tolerance limit is dynamic and a function of at least one of a current or an age of the energy storage module.

2. A system according to claim 1, wherein the control circuit is configured to: determine the reference value or reference change of the specific parameter based on the sensor measurement results generated by the first group of sensors associated with the energy storage module and one or more of the following: (i) sensor measurement results generated by a second group of sensors associated with a different second energy storage module; (ii) inherent characteristics of the energy storage module; or (ii) historical information about the energy storage module or about other energy storage modules.

3. The system of claim 1 , wherein in response to detecting the deviation condition, the control circuit is configured to: identify a particular sensor in the first set of sensors that generated the sensor measurement on which the deviated monitored value or the deviated monitored change is based, and The control circuit is configured to estimate the cause of the deviation condition by comparing the sensor measurement results generated by the particular sensor with the following: sensor measurements generated by other sensors in the first group of sensors; or sensor measurements generated by other sensors in the second group of sensors associated with a different second energy storage module.

4. The system of claim 1 , wherein in response to detecting the deviation condition, the control circuit is configured to generate a control signal configured to change one or more operating conditions of the energy storage module.

5. The system of claim 4, wherein the control signal is configured to change one or more operating conditions of the energy storage module by one or more of: preventing current delivery from the energy storage module; adjusting a non-zero rate of current transfer from the energy storage module; Adjusting an ambient temperature around the energy storage module; adjusting a rate of temperature regulation around the energy storage module; sensing a specified load on the energy storage module; initiating active cooling; initiating fire suppression; or marking the energy storage module for repair.

6. The system of claim 4, wherein the control circuit is configured to: identify a particular sensor in the first set of sensors that generated a sensor measurement on which the deviated monitored value or the deviated monitored change is based, and The control circuit is configured to monitor additional sensor measurements generated by the particular sensor during a determined time period after changing one or more operating conditions of the energy storage module, and the control circuit is configured to estimate a cause of the deviation condition based at least in part on the additional sensor measurements generated by the particular sensor during the determined time period. 7 . The system of claim 1 , wherein the control circuit is further configured to detect the deviation condition independent of any of the sensor measurements exceeding a preset threshold.

8. The system of claim 1 , wherein one or more energy storage devices of the energy storage module are batteries, and The energy storage module includes one or more of a single battery cell, an assembly of multiple battery cells connected in series with each other, or an assembly of multiple battery cells connected in parallel with each other.

9. The system of claim 1, wherein the specific parameter is one of temperature, voltage, current, power, state of charge, charge capacity, pressure, coolant flow rate, or resistance.

10. The system of claim 1 , wherein the control circuit is configured to determine a reference value or reference change for the specific parameter based on a physics-based model that incorporates inherent characteristics of the energy storage module, operating conditions of the energy storage module, and historical information about the energy storage module.

11. The system of claim 1 , wherein the control circuit is configured to determine the reference value or reference change of the particular parameter at least in part by compiling sensor measurements generated by the first set of sensors.

12. The system of claim 1, wherein the control circuit and the first set of sensors are disposed on a vehicle that is at least partially propelled by the energy storage module.

13. A method comprising: obtaining sensor measurements generated by a first set of sensors associated with an energy storage module, the energy storage module comprising one or more energy storage devices, the sensor measurements representing one or more parameters of the energy storage module; determining one or more of a reference value or a reference change over time for a particular one of the one or more parameters based at least in part on the sensor measurements; comparing one or more of the monitored values ​​or monitored changes of the particular parameter based on sensor measurements generated by the first set of sensors with a reference value or reference change of the particular parameter; a deviation condition is detected in response to one or more of: (i) a rate of change of the monitored value differing from a rate of change of the reference value by more than a specified tolerance margin for the rate of change, or (ii) a monitored change between two monitored values ​​of the particular parameter exceeding the reference change by more than a specified tolerance margin for the change, wherein the two monitored values ​​defining the monitored change are based on sensor measurements generated by two different sensors of the first set of sensors, The control circuit is configured to determine a reference value or a reference change for the specific parameter based on sensor measurements generated by a first set of sensors associated with the energy storage module and an operating condition of the energy storage module, and wherein the specified tolerance limit is dynamic and a function of at least one of a current or an age of the energy storage module.

14. The method according to claim 13, further comprising: In response to detecting the deviation condition, a control signal is generated to change one or more operating conditions of the energy storage module.

15. The method according to claim 14, further comprising: The cause of the deviation condition is estimated by comparing sensor measurements generated by a first sensor in the first set of sensors before changing one or more operating parameters of the energy storage module with sensor measurements generated by the first sensor after changing the one or more operating parameters.

16. The method of claim 14, wherein the control signal is configured to change the one or more operating conditions by one or more of: adjusting the ambient temperature around the energy storage module; adjusting the rate at which the temperature around the energy storage module is adjusted; sensing a specified load on the energy storage module; replacing at least one of the sensors; preventing the current transfer operation of the energy storage module; adjusting the non-zero rate of current transfer of the energy storage module; Initiate active cooling; initiate fire suppression; or tag the energy storage module for repair.

17. The method of claim 13, further comprising determining a reference value or reference change for the specific parameter based on sensor measurements generated by the first set of sensors associated with the energy storage module and one or more of: sensor measurements generated by a second set of sensors associated with a different second energy storage module; inherent characteristics of the energy storage module; or historical information about the energy storage module or about other energy storage modules.

18. The method of claim 13, further comprising: The cause of the deviating condition is estimated by comparing a sensor measurement generated by a first sensor in the first group of sensors on which the deviated monitoring value or the deviated monitoring change is based with sensor measurements generated by other sensors in the first group of sensors, or sensor measurements generated by a second group of sensors associated with a different second energy storage module.

19. The method of claim 13, wherein the specific parameter is one of temperature, voltage, current, power, state of charge, charge capacity, pressure, coolant flow rate, or resistance.

20. A system comprising: a control circuit comprising one or more processors, the control circuit being configured to: obtain sensor measurements generated by a first set of sensors associated with an energy storage module, the energy storage module comprising one or more energy storage devices, the sensor measurements representing one or more parameters of the energy storage module; wherein the control circuitry is configured to compare a sensor measurement representative of a particular parameter of the one or more parameters with one or more of a reference value or a reference change for the particular parameter, wherein the reference value or the reference change is based at least in part on the sensor measurement, and the control circuitry is configured to detect a deviation condition in response to one or more of: (i) a rate of change of the monitored value differing from a rate of change of the reference value by more than a specified tolerance margin for rate of change, or (ii) a monitored change between two monitored values ​​of the particular parameter exceeding the reference change by more than a specified tolerance margin for change, wherein the two monitored values ​​defining the monitored change are based on sensor measurements generated by two different sensors of the first group of sensors, and wherein in response to detecting the deviation condition, the control circuit is configured to: identify a first sensor in the first group of sensors that generated one or more sensor measurements that deviate from a reference value or reference variation; estimate a cause of the deviation condition based at least in part on the sensor measurements generated by the first sensor; and generating a control signal to initiate one or more remedial actions based on the estimated cause, wherein the control circuit is configured to determine a reference value or a reference change of the specific parameter based on sensor measurements generated by a first set of sensors associated with the energy storage module and an operating condition of the energy storage module, and wherein the specified tolerance limit is dynamic and a function of at least one of a current or an age of the energy storage module.

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