Battery system, method for implementing a battery control system, and computer readable medium

Abstract

One embodiment of the present disclosure describes a battery system, the battery system comprising: a battery string having first and second battery modules; and a battery control system. The battery control system comprises: a first battery cell controller, the first battery cell controller determining a first module-level operating parameter related to the operation of the first battery module; a second battery cell controller, the second battery cell controller determining a second module-level operating parameter related to the operation of the second battery module; a string control unit, the string control unit determining a string-level operating parameter related to the operation of the battery string at least partially based on the first and second module-level operating parameters in a communication manner; and a system control unit, the system control unit determining a system-level operating parameter related to the operation of the battery system at least partially based on the string-level operating parameter, and controlling the operation of the battery system at least partially based on the system-level operating parameter.

Description

[0001] This application is a divisional application of the Chinese invention patent application with the application date of October 28, 2016, the international application number of PCT / US2016 / 059267, the national application number of 2016800637182, and the invention name of "Battery System, Method for Implementing Battery Control System and Computer-readable Medium".

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to and the benefit of U.S. Provisional Application Serial No. 62 / 250,989, filed on November 4, 2015, and entitled “FLEXIBLE SCALABLE BATTERY MANAGEMENT SYSTEM,” which is incorporated herein by reference in its entirety for all purposes. Background Art

[0004] The present disclosure relates generally to battery systems and, more particularly, to battery control systems used in battery systems.

[0005] This section is intended to introduce the reader to various areas of technology that may be related to various aspects of this disclosure, which are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of various aspects of this disclosure. Therefore, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

[0006] Electrical systems typically include a battery system for capturing (e.g., storing) generated electrical energy and / or for supplying electrical power. In practice, a battery system can be included in electrical systems for a variety of applications and / or having different configurations. For example, a stationary power system may include a battery system that receives power output by a generator and stores the power as electrical energy. In this way, the battery system can use the stored electrical energy to supply power to electrical loads.

[0007] In addition, the electrical system in a motor vehicle may include, for example, a battery system that supplies electricity to provide and / or supplement the motive force (e.g., power) of the motor vehicle. For the purposes of this disclosure, such a motor vehicle is referred to as an xEV and may include any one, any variant, and / or any combination of the following types of motor vehicles. For example, an electric vehicle (EV) may use a battery-powered electric propulsion system (e.g., one or more motors) as the primary source of motive force for the vehicle. In this way, the battery system in the electric vehicle may be implemented to supply electricity to the battery-powered electric propulsion system. In addition, a hybrid electric vehicle (HEV) may utilize a combination of a battery-powered electric propulsion system and an internal combustion engine propulsion system to generate the vehicle motive force. In this way, the battery system may be implemented to facilitate directly providing at least a portion of the vehicle motive force by supplying electricity to the battery-powered electric propulsion system.

[0008] In addition, micro-hybrid electric vehicles (mHEVs) can use an internal combustion engine propulsion system as the main source of vehicle motive power, but can utilize a battery system to implement "start-stop" technology. Specifically, an mHEV can deactivate the internal combustion engine when idling and crank (e.g., restart) the internal combustion engine when propulsion is desired. To facilitate the implementation of such technology, the battery system can continue to supply power when the internal combustion engine is deactivated, and supply power to crank the internal combustion engine. In this way, the battery system can indirectly supplement the provision of vehicle motive power.

[0009] In any case, the battery system may include a battery control system that controls (e.g., monitors and / or manages) the operation of the battery system. For example, the battery control system may determine operating parameters of the battery system (e.g., voltage and / or current) and command the battery system to adjust its operation based at least in part on the operating parameters. Thus, the implementation of the battery control system may vary based at least in part on the implementation (e.g., configuration and / or organization) of the battery system. However, in some cases, the implementation of the battery system may vary based at least in part on the target application and / or configuration of the electrical system utilizing the battery system. Summary of the Invention

[0010] The following summarizes certain embodiments commensurate with the scope of this disclosure. These embodiments are not intended to limit the scope of this disclosure, but rather to provide a brief overview of certain disclosed embodiments. In fact, this disclosure can encompass various forms that may be similar or different from the embodiments set forth below.

[0011] The present disclosure generally relates to battery systems, for example, for use in electrical systems to capture (e.g., store) electrical energy and / or use the stored electrical energy to supply electrical power. In some embodiments, the battery system may include a battery control system for controlling the operation of the battery system. To facilitate the control operation, the battery control system may perform various functions, such as determining operating parameters related to the operation of the battery system and / or determining control commands that instruct the battery system to perform control actions.

[0012] In some embodiments, the functions to be performed by the battery control system may depend on the implementation (e.g., hierarchical organization) of the battery system. However, in some cases, the implementation of the battery system used in different electrical systems and / or different target applications may be different. Thus, the functions performed by different battery control systems, and therefore their implementation, may vary.

[0013] To facilitate increased implementation flexibility, the present disclosure provides techniques for determining a hybrid battery control system architecture that can be utilized to implement a variety of different battery control systems with reduced implementation-related costs. In some embodiments, a hybrid battery control system can include basic (e.g., standard) building blocks that can be used to implement a battery control system. For example, the hybrid battery control system architecture can specify a cell control unit, a string control unit, and a system control unit, as well as the functionality provided by each and the infrastructure within each for providing the corresponding functionality.

[0014] Thus, in some embodiments, the design system can determine the hybrid battery control system architecture based at least in part on a target control level (e.g., granularity) and / or target functionality to be provided by the battery control system, the battery control system being intended to be compatible (e.g., implementable) using building blocks provided in the hybrid battery control system architecture. To facilitate determining the target control level and / or target functionality, in some embodiments, the design system can analyze a battery system corresponding to the battery control system. In this manner, the design system can determine an implementation (e.g., hierarchical organization) of the battery system.

[0015] For example, when the battery system includes a battery module having a plurality of battery cells, the design system may determine that the target control level includes a battery cell control level and / or a module control level. Additionally, the design system may determine that the target function includes a module-level function such as determining the voltage of the battery module, and / or a battery cell-level function such as determining the voltage of one or more battery cells. Additionally, when the battery system includes a battery string having a plurality of battery modules connected in series, the design system may determine that the target control level includes a string control level, and the target function includes a string-level function such as determining an operating parameter (e.g., voltage or current) of the battery string and / or coordinating the operation of the battery modules. Additionally, when the battery system includes a plurality of battery strings, the design system may determine that the target control level includes a system control level, and the target function includes a system-level function such as coordinating the operation of the battery string.

[0016] In some cases, a battery control system may be implementable using any of a number of different battery control system architectures. However, each of these different battery control system architectures may have a different impact on implementation flexibility and / or implementation-related costs. Therefore, in some embodiments, the design may select the hybrid battery control system architecture from a number of candidates, for example, by using an objective function that provides a metric indicating expected implementation flexibility and / or expected implementation-related costs for each candidate.

[0017] In some embodiments, to determine implementation flexibility, the design system may determine the number of different battery control systems that a candidate battery control system architecture can implement and / or the number of target functions for the different battery control systems. Additionally, to facilitate determining implementation-related costs, the design system may determine the infrastructure used in the candidate battery control system architecture. In some embodiments, implementation-related costs may be reduced by reducing the number of microprocessors, isolation barriers, and / or communication infrastructure used to implement the battery control system.

[0018] To facilitate increased implementation flexibility and / or reduced implementation-related costs, in some embodiments, the hybrid battery control system architecture determined by the design system may group functions into the building blocks based at least in part on voltage domains and / or control level hierarchies. Additionally, in some embodiments, the hybrid battery control system architecture may distribute less computationally intensive functions, for example, in battery cell control units, to facilitate increased implementation flexibility. On the other hand, in some embodiments, the hybrid battery control system architecture may centralize more computationally intensive processing functions, for example, in string control units, to facilitate reducing the number of microprocessors and thereby reducing implementation-related costs. Additionally, in some embodiments, the hybrid battery control system architecture may centralize communications between components operating in different voltage domains (e.g., ranges), for example, in string control units, to facilitate reducing the number of isolation barriers and thereby reducing implementation-related costs.

[0019] Additionally, in some embodiments, the hybrid battery control system architecture may include an integrated string control unit that integrates the functionality of a cell control unit and a string control unit. In other words, instead of separate string control units and cell control units, the battery system may be implemented using an integrated string control unit. Implementing the battery control system using an integrated string control unit in this manner can facilitate a reduction in communication infrastructure and, therefore, implementation-related costs.

[0020] Additionally, in some embodiments, the hybrid battery control system architecture can enable string control units (e.g., integrated string control units) to be communicatively coupled via a serial communication network, for example, using one or more serial communication buses such as a ripcord bus. In some embodiments, the serial communication network can communicatively couple string control units in a daisy chain, for example, with a master string control unit and one or more slave control units. Utilizing the serial communication network, the string control units can communicate serial communication signals that facilitate self-configuration and / or fault indication.

[0021] For example, the master string control unit may generate a serial communication signal having a master frequency (e.g., 100 Hz) indicating that it is the master string control unit. Additionally, the master string control unit may generate a serial communication signal having a fault frequency indicating that a fault has been detected. The master string control unit may then transmit the serial communication signal to the slave string control units via a serial communication bus.

[0022] Thus, based at least in part on the frequency of the serial communication signal, a slave string control unit can determine whether a fault has been detected in the battery system. When a fault has been detected, the slave string control unit can output a serial communication signal having a fault frequency indicating that the fault has been detected. On the other hand, when no fault has been detected, the slave string control unit can determine its order in the serial communication network based at least in part on the received frequency. For example, when the received frequency is equal to the master frequency, the string control unit can determine that it is the first slave string control unit in the serial communication network.

[0023] In addition, the slave string control unit can determine a sequential frequency indicating its order in the serial communication network. In some embodiments, the sequential frequency can be a fraction of the received frequency. For example, the sequential frequency (e.g., 50 Hz) determined by the first slave string control unit in the serial communication network can be half of the received frequency and therefore half of the master frequency (e.g., 100 Hz). The first slave string control unit can then pass the serial communication signal having the sequential frequency to the next slave string control unit in the serial communication network. In this way, the next slave string control unit can determine that its order in the serial communication network is the second slave string control unit.

[0024] To facilitate fault detection, in some embodiments, the hybrid battery control system architecture may provide a battery cell control unit fault detection capability. However, in some embodiments, the hybrid battery control system architecture may include limited processing capabilities within the battery cell control unit to facilitate reducing implementation-related costs. For example, instead of a microprocessor, the battery cell control unit may include a first analog-to-digital (ADC) converter, a second analog-to-digital converter, and logic circuitry that performs logical and / or arithmetic operations based on circuit connections formed within the logic circuitry.

[0025] Therefore, in order to improve the reliability of the battery system, the battery cell control unit can be implemented to provide fault detection even with limited processing power. For example, in some embodiments, a first analog-to-digital converter can receive sensor data (e.g., an analog representation) from a voltage sensor and generate a first battery cell group voltage (e.g., a digital representation) indicating the voltage measured across a first battery cell group in the battery module. Additionally, a second analog-to-digital converter can receive sensor data from a voltage sensor and generate a second battery cell group voltage indicating the voltage measured across a second battery cell group in the battery module. Additionally, the second analog-to-digital converter can receive sensor data from a voltage sensor and generate a measured battery cell group voltage (e.g., a digital representation) indicating the voltage measured across the battery module.

[0026] Based at least in part on the first battery cell group voltage and the second battery cell group voltage, the logic circuit system can determine a calculated battery module voltage, for example, by adding the first battery cell group voltage to the second battery cell group voltage. In addition, to determine whether a fault is expected, the logic circuit system can compare the calculated battery module voltage with the measured battery module voltage. For example, in some embodiments, when the voltage difference between the calculated battery module voltage and the measured battery module voltage is greater than a difference threshold, the logic circuit system can determine that a fault is expected. In this way, a hybrid battery control system architecture that improves implementation flexibility and / or reduces implementation-related costs can be determined and used to implement various battery control systems. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings, in which like reference numerals represent like parts throughout, wherein:

[0028] Figure 1 is a block diagram of an electrical system including a battery system according to an embodiment of the present disclosure;

[0029] Figure 2 is a perspective view of a motor vehicle having the electrical system battery system of claim 1 according to an embodiment of the present disclosure;

[0030] Figure 3 According to the embodiment of the present disclosure Figure 2 a schematic diagram of a motor vehicle;

[0031] Figure 4 According to the embodiment of the present disclosure Figure 1 A block diagram of a battery system including a battery control system;

[0032] Figure 5 According to an embodiment of the present disclosure, Figure 4 The block diagram of the target architecture of the battery control system is designed;

[0033] Figure 6 is used to operate according to an embodiment of the present disclosure Figure 6 Flowchart of the process of designing a system;

[0034] Figure 7 According to an embodiment of the present disclosure, Figure 4 A flow chart of the target functional process of the battery control system;

[0035] Figure 8 According to an embodiment of the present disclosure, Figure 4A flowchart of a process for implementing an infrastructure of a target function in a battery control system;

[0036] Figure 9 According to the embodiment of the present disclosure Figure 4 A block diagram of a battery system, wherein the battery control system is implemented using a battery cell control unit, a string control unit, and a system control unit based on an exemplary architecture;

[0037] Figure 10 According to the embodiment of the present disclosure Figure 9 A block diagram of the system control unit;

[0038] Figure 11 According to the embodiment of the present disclosure Figure 9 Block diagram of a string control unit;

[0039] Figure 12 According to the embodiment of the present disclosure Figure 9 A block diagram of a battery cell control unit;

[0040] Figure 13 According to the embodiment of the present disclosure Figure 4 A block diagram of a battery system, wherein the battery control system is implemented based on another exemplary architecture using a battery cell control unit, an integrated string control unit, and a system control unit;

[0041] Figure 14 According to the embodiment of the present disclosure Figure 13 A block diagram of an integrated string control unit;

[0042] Figure 15 According to the embodiment of the present disclosure, Figure 14 A flow chart of a process of an integrated string control unit;

[0043] Figure 16 is a block diagram of a master string control unit and slave string control units communicatively coupled via a serial communication bus in a daisy chain according to an embodiment of the present disclosure;

[0044] Figure 17 According to an embodiment of the present disclosure, Figure 16 Flowchart of the process of transmitting serial communication signals in a daisy chain of serial communication buses;

[0045] Figure 18 is a flow chart of a process for operating a slave string control unit based at least in part on a serial communication signal according to an embodiment of the present disclosure;

[0046] Figure 19 According to the embodiment of the present disclosure, Figure 16a drawing of exemplary serial communication signals output by a string control unit in a daisy-chain of serial communication buses;

[0047] Figure 20 is a block diagram of a battery module and a battery cell control unit in a battery system according to an embodiment of the present disclosure; and

[0048] Figure 21 is used for operation according to an embodiment Figure 20 A flow chart of the process of a battery cell control unit to detect a fault. DETAILED DESCRIPTION

[0049] One or more specific embodiments of the present disclosure are described below. In order to provide a concise description of these embodiments, not all features of the actual implementation are described in the specification. It should be understood that in the development of any such actual implementation (as in any engineering or design scheme), a large number of implementation-specific decisions must be made to achieve the developer's specific goals (such as compliance with system-related and business-related constraints), which goals may vary from one implementation to another. In addition, it should be understood that such development work may be complex and time-consuming, but it is still a routine design, production and manufacturing work for ordinary technicians who benefit from this disclosure.

[0050] Typically, a battery system can be implemented to capture (e.g., store) electrical energy generated by one or more generators and / or use the stored electrical energy to supply power to one or more electrical loads. Taking advantage of these benefits, one or more battery systems are often included in electrical systems. In practice, battery systems can be used in electrical systems with varying configurations to implement a wide variety of target applications, ranging from stationary power systems to vehicle electrical systems, for example.

[0051] To facilitate the implementation of different target applications, the configuration of the electrical system and, therefore, the configuration of the battery system used in the electrical system can be adjusted. For example, in one target application, the electrical system may include a first electrical load (e.g., a component) designed to operate using power in a high-voltage domain (e.g., 48V, 600V, or 720V), and a second electrical load designed to operate using power in a low-voltage domain (e.g., 3V, 5V, or 12V). In this way, the battery system can be implemented to supply power to the first electrical load in the high-voltage domain.

[0052] In some embodiments, to facilitate providing a high voltage domain, the battery system can be implemented with multiple battery modules (e.g., battery packs) connected in series into one or more battery strings. Additionally, to facilitate providing sufficient power to operate a first electrical load, in some embodiments, the battery system can be implemented with multiple battery modules and / or multiple battery strings connected in parallel. Furthermore, the battery system and / or an external power source can be implemented to supply power to a second electrical load in a low voltage domain.

[0053] In order to control operation (e.g., storage of electrical energy and / or supply of electrical power), the battery system may include a battery control system. Specifically, the battery control system may control the operation of the battery system by performing various functions, such as determining operating parameters related to the operation of the battery system (e.g., voltage, current, and / or temperature), communicating the operating parameters within the battery control system, communicating the operating parameters to an external communication network, and / or determining control commands that instruct the battery system to perform control actions. For example, the battery control system may determine operating parameters of a battery module, one or more battery modules, one or more battery strings, and / or one or more battery cells in the battery system as a whole. In addition, the battery control system may communicate the operating parameters to a supervisory control system that coordinates the operation of subsystems in the electrical system. Furthermore, when a fault is detected, the battery control system may communicate a control command that instructs a relay (e.g., a circuit breaker) to open.

[0054] In some cases, the functionality provided by a battery control system may depend on the implementation (e.g., hierarchical organization) of the corresponding battery system. However, as described above, the implementation of the battery system may vary when used in different electrical systems and / or different target applications. In other words, the battery control system for different battery systems may vary in implementation, such as in the functionality provided and / or the level of control (e.g., granularity).

[0055] In some embodiments, a battery control system can be implemented using a battery control system architecture. For example, a purely centralized battery control system architecture can be designed for a specific battery control system and thus limit implementation flexibility (e.g., the number of compatible battery system variants). At the other extreme, a purely distributed battery control system architecture can increase the amount of redundant infrastructure to improve implementation flexibility, but incurs increased implementation-related costs.

[0056] Thus, the present disclosure provides techniques for determining a hybrid battery control system architecture that, for example, increases implementation flexibility and / or reduces implementation-related costs. In some embodiments, a hybrid battery control system may include basic (e.g., standard) building blocks that can be used to implement a battery control system. For example, a hybrid battery control system architecture may provide a specific infrastructure for a cell control unit to provide specific cell-level functionality and / or module-level functionality. Additionally, a hybrid battery control system architecture may provide a specific infrastructure for a string control unit to provide specific string-level functionality. Furthermore, a hybrid battery control system architecture may provide a specific infrastructure for a system control unit to provide specific system-level functionality.

[0057] In some embodiments, the design system may determine the hybrid battery control system architecture based at least in part on a target control level (e.g., granularity) and / or target functionality to be provided by the battery control system, the battery control system being intended to be implementable using building blocks provided in the hybrid battery control system architecture. Additionally, in some embodiments, the design system may determine the hybrid battery control system architecture based at least in part on the infrastructure (e.g., processing, power, and / or communication infrastructure) expected to be used to implement the target functionality.

[0058] To facilitate determining a hybrid battery control system architecture, in some embodiments, the design system can analyze multiple candidates using an objective function. In some embodiments, the objective function can provide metrics associated with the candidate that indicate expected implementation flexibility and / or expected implementation-related costs. For example, in some embodiments, the objective function can target reducing the number of processors, reducing the number of isolation barriers, and / or reducing communication infrastructure. In this manner, the design system can select a hybrid battery control system architecture from the multiple candidates.

[0059] In some embodiments, the hybrid battery control system architecture can group functionality into building blocks based, at least in part, on voltage domains and / or control level hierarchies. For example, the hybrid battery control system architecture can group measurement functionality associated with a battery module and / or battery cells within a battery module within a battery cell control unit. Additionally, in some embodiments, the hybrid battery control system architecture can centralize external communication functionality (e.g., from the battery control system) within the system control unit, thereby reducing the communication infrastructure required to implement external communication functionality.

[0060] Furthermore, in some embodiments, the hybrid battery control system architecture can centralize more computationally intensive processing functions into a single building block. For example, the hybrid battery control system architecture can centralize more computationally intensive processing functions into a string control unit, thereby reducing the processing infrastructure required to implement the processing functions. Alternatively, the hybrid battery control system architecture can distribute less computationally intensive functions across multiple different building blocks. For example, the hybrid battery control system architecture can distribute less computationally intensive processing functions across a cell control unit, a string control unit, and a system control unit, thereby increasing implementation flexibility by providing multiple different levels of control (e.g., granularity).

[0061] Additionally, in some embodiments, the hybrid battery control system architecture can centralize communication functionality between components operating in different voltage domains (e.g., within the battery control system) into a single building block. For example, the hybrid battery control system architecture can centralize communication between electrical components operating in different voltage domains into a string control unit. In this way, other building blocks can be implemented without isolation barriers, thereby reducing the power infrastructure required to implement communication functionality.

[0062] As described above, a battery string may include one or more battery modules connected in series. In other words, a battery string generally includes at least one battery module. Therefore, in some embodiments, the hybrid battery control system architecture may include an integrated string control unit that integrates the functionality of a battery cell control unit and a string control unit. In other words, instead of separate string control units and battery cell control units, the battery system may include a single integrated string control unit. In this way, the hybrid battery control system architecture may facilitate reducing communication infrastructure - particularly in less complex battery systems (e.g., single battery module battery strings). In fact, in some embodiments, the use of an integrated string control unit may avoid the use of a system control unit, for example in a battery system with a single battery module and / or a single battery string.

[0063] In some embodiments, the string control units (e.g., integrated string control units) can be communicatively coupled via a parallel (e.g., primary) communication network, such as a controller area network (CAN). To improve the reliability of the battery control system, the string control units can also be communicatively coupled via a serial (e.g., backup) communication network via one or more serial communication buses, such as a ripcord bus. In some embodiments, the serial communication network can communicatively couple the string control units in a daisy chain, for example, with a master (e.g., first) string control unit and one or more slave (e.g., second) control units.

[0064] Additionally, in some embodiments, the serial communication network can enable the string control units to communicate serial communication signals for facilitating self-configuration and / or fault indication. In some embodiments, the string control units can generate serial communication signals having a frequency that indicates their order in the serial communication network and / or whether a fault has been detected in the battery system. For example, when no fault has been detected, the first string control unit can generate a serial communication signal having a master frequency that indicates it is the master string control unit. On the other hand, when a fault has been detected, the first string control unit can generate a serial communication signal having a fault frequency that indicates that a fault has been detected in the battery system.

[0065] By outputting a serial communication signal to the serial communication bus, the string control unit can enable subsequent string control units in the serial communication network to determine that a fault has been detected. For example, when a second string control unit receives a serial communication signal having a fault frequency from a first string control unit, the second string control unit can confirm that a fault has been detected and output a serial communication signal having the fault frequency after the fault has been confirmed to indicate that a fault has been detected in the battery system.

[0066] In addition, by outputting the serial communication signal to the serial communication bus, the string control unit can enable the slave string control units to determine their order in the serial communication network. For example, when the second string control unit receives the serial communication signal having the master frequency from the first string control unit, the second string control unit can determine that the first string control unit is the master string control unit and, therefore, is the first slave string control unit in the serial communication network.

[0067] The slave string control unit can also determine a sequence frequency that indicates its order in the serial communication network. In some embodiments, the sequence frequency can be a fraction of the received frequency. For example, the sequence frequency determined by the second string control unit can be half of the received frequency, and therefore half of the master frequency. Therefore, by passing the serial communication signal with its sequence frequency to the third string control unit in the serial communication network, the string control unit can enable the third string control unit to determine that it is the second slave string control unit in the serial communication network.

[0068] As described above, the string control unit can determine whether a fault is expected to occur in the string control unit, a battery cell control unit communicatively coupled to the battery cell control unit, and / or a battery module electrically coupled to the battery cell control unit. Furthermore, as described above, the hybrid battery control system architecture can centralize computationally intensive functions within the string control unit. Thus, in some embodiments, the string control unit can include a processor (e.g., a processor unit and / or processing circuitry) that enables the string control unit to perform more complex data analysis operations to detect faults.

[0069] On the other hand, in some embodiments, the hybrid battery control system architecture can provide a battery cell control unit with limited processing power to facilitate reducing implementation-related costs. However, this may limit the complexity of the data analysis operations that the battery cell control unit can perform. For example, instead of a processor, the battery cell controller can include a first analog-to-digital (ADC) converter that determines an indication of an operating parameter (e.g., voltage) of a first group of battery cells in the battery module, a second ADC that determines an indication of an operating parameter (e.g., voltage) of a second group of battery cells in the battery module, and logic circuitry.

[0070] In some embodiments, the logic circuitry may perform logical operations and / or arithmetic operations based on circuit connections formed within the logic circuitry. For example, the logic circuitry may include arithmetic circuitry, such as one or more logic gates. Additionally, the logic circuitry may include comparison circuitry, such as one or more operational amplifiers. Thus, in some embodiments, the processing capabilities of the logic circuitry may be more limited than those of the processor.

[0071] Nevertheless, the hybrid battery control system architecture can enable the battery cell control unit to be implemented with fault detection capabilities. For example, a first analog-to-digital converter can determine an indication (e.g., a digital representation) of a first battery cell group voltage. Additionally, a second analog-to-digital converter can determine an indication of a second battery cell group voltage and a first indication of a battery module voltage. Based at least in part on the first battery cell group voltage and the second battery cell group voltage, the logic circuit system can determine a second indication of the battery module voltage. Additionally, the logic circuit system can compare the first indication of the battery module voltage with the second indication of the battery module voltage to determine whether a fault is expected in the battery cell control unit. For example, the logic circuit system can determine that a fault is expected when the difference between the two is greater than a threshold value (e.g., a voltage or percentage). In this way, a hybrid battery control system architecture that improves implementation flexibility and / or reduces implementation-related costs can be determined and used to implement various battery control systems.

[0072] To help illustrate, Figure 1 1 shows an electrical system 10 including a battery system 12. In addition to the battery system 12, the electrical system 10 also includes a power source 14, an electrical load 16, and a supervisory control system 18. In some embodiments, the supervisory control system 18 can control the operation of the electrical system 10. For example, the supervisory control system 18 can determine operating parameters of subsystems in the electrical system 10 (e.g., the battery system 12, the power source 14, and / or the electrical load 16) and / or coordinate the operation of the subsystems.

[0073] To facilitate control operations, the supervisory control system 18 may include a supervisory processor 20 and a supervisory memory 22. In some embodiments, the supervisory memory 22 may include a tangible, non-transitory computer-readable medium storing instructions executable by the supervisory processor 20. Thus, in such embodiments, the supervisory memory 22 may include random access memory (RAM), read-only memory (ROM), rewritable non-volatile memory (e.g., flash memory), a hard drive, an optical disk, etc. Additionally, the supervisory processor 20 may include one or more general-purpose processing units and / or processing circuitry. For example, the supervisory processor 20 may include one or more microprocessors, one or more application-specific integrated circuits (ASICs), and / or one or more field-programmable logic arrays (FPGAs).

[0074] As described above, the battery system 12 can store the received power as electrical energy and use the stored electrical energy to supply electricity. Thus, as depicted, the battery system 12 is electrically connected to the power source 14, which can enable the power source 14 to supply power to the battery system 12. In some embodiments, the power source 14 can include one or more machines, components, and / or devices that output power. For example, the power source 14 can be an electrical grid, a generator, an AC generator, an energy storage system (e.g., another battery system), etc.

[0075] Additionally, as depicted, the battery system 12 is electrically connected to an electrical load 16, which enables the battery system 12 to supply power to the electrical load 16. In some embodiments, the electrical load 16 may include one or more machines, components, and / or devices that use electricity to perform operations and / or capture electricity as electrical energy. For example, the electrical load 16 may include a computer, an engine control unit, a display, a light bulb, an electric motor, an energy storage system (e.g., another battery system), a heating, ventilation, and air conditioning (HVAC) system, and the like.

[0076] In the depicted embodiment, the battery system 12 includes one or more battery modules 24 and a battery control system 26. In some embodiments, the battery control system 26 may control the operation of the battery system 12. For example, the battery control system 26 may determine operating parameters of the battery modules 24, coordinate the operation of the plurality of battery modules 24, transmit control commands instructing the battery system 12 to perform control actions, and / or communicate with the supervisory control system 18.

[0077] To facilitate control operations, the battery control system 26 may include a processor 28 and a memory 30. In some embodiments, the memory 30 may include a tangible, non-transitory computer-readable medium that stores data, such as instructions executable by the processor 28, results determined by the processor 28 (e.g., operating parameters), and / or information to be analyzed / processed by the processor 28 (e.g., operating parameters). Thus, in such embodiments, the memory 30 may include random access memory (RAM), read-only memory (ROM), rewritable non-volatile memory (e.g., flash memory), a hard drive, an optical disk, etc. Additionally, the processor 28 may include one or more general-purpose processing units, processing circuitry, and / or logic circuitry. For example, the processor 28 may include one or more microprocessors, one or more application-specific integrated circuits (ASICs), and / or one or more field-programmable gate arrays (FPGAs).

[0078] In addition, to facilitate storing electrical energy and supplying electrical power, the battery system 12 may include one or more battery modules 24. In some embodiments, the storage capacity of the battery system 12 may be based at least in part on the number of battery modules 24. Additionally, in some embodiments, the operational compatibility of the battery system 12 with the electrical system 10 may be based at least in part on the configuration of the battery modules 24, such as in series and / or in parallel to operate within a target voltage domain. Accordingly, in some embodiments, the implementation (e.g., number and / or configuration) of the battery modules 24 and, therefore, the battery system 12 may vary based at least in part on the configuration and / or target application of the electrical system 10.

[0079] However, as described above, the electrical system 10 can be used in a wide range of applications. As such, the implementations of different battery systems 12 can vary from one another. For example, in some embodiments, the electrical system 10 can be included in a stationary power system, an industrial system, a manufacturing system, an automation system, or the like, such as a factory or workshop. Additionally, in some embodiments, the electrical system 10 can be included in a computing system such as a computer or a motor vehicle such as a motor vehicle (e.g., an airplane, a ship, a truck, or a car).

[0080] To provide examples of possible applications, Figure 2 1 shows a motor vehicle 32 utilizing the first battery system 12A. The discussion regarding the motor vehicle 32 is intended merely to help illustrate the disclosed technology and does not limit the scope of the technology. In some embodiments, the motor vehicle 32 may be an xEV that utilizes the battery system 12 to provide and / or supplement vehicle motive force, such as for accelerating and / or decelerating the motor vehicle 32. In other embodiments, the motor vehicle 32 may be a conventional motor vehicle 32 that generates vehicle motive force, such as using an internal combustion engine for acceleration and / or friction brakes for deceleration.

[0081] Figure 3 , a more detailed view of the first battery system 12A and the electrical system 10 in a motor vehicle 32 is shown in FIG. As described above, the battery system 12 includes a battery control system 26 and one or more battery modules 24. Additionally, as described above, in addition to the battery system 12, the electrical system 10 may also include a power source 14, an electrical load 16, and a supervisory control system 18. For example, in the depicted motor vehicle 32, the electrical loads 16 may include a vehicle console 38 and a heating, ventilation, and air conditioning (HVAC) system 37. In some embodiments, the electrical loads 16 may additionally or alternatively include a mechanical energy source 40 (e.g., an electric motor) operating in a motor mode.

[0082] Additionally, in the depicted motor vehicle 32, the power source 14 includes an alternator 42 that can convert mechanical energy generated by the mechanical energy source 40 (e.g., an internal combustion engine and / or rotating wheels) into electrical energy. In some embodiments, the power source 14 can additionally or alternatively include the mechanical energy source 40 (e.g., an electric motor) operating in a generator mode.

[0083] As depicted, the motor vehicle 32 also includes a vehicle control system 43. In some embodiments, the vehicle control system 43 can generally control the operation of the motor vehicle 32, including the electrical system 10. Thus, in the depicted motor vehicle 32, the supervisory control system 18 can be included in the vehicle control system 43. However, the vehicle control system 43 can additionally control the operation of other components besides the electrical system 10, such as an internal combustion engine propulsion system.

[0084] As described above, the number and / or configuration of battery modules 24 in different battery systems 12 can vary based at least in part on the target application. For example, in the depicted motor vehicle 32, the battery system 12 includes two battery modules 24, namely a first battery module 24A and a second battery module 24B. In some embodiments, the first battery module 24A can include one or more battery cells 36 connected in series and / or in parallel with the terminals of the first battery module 24A. Similarly, in some embodiments, the second battery module 24B can include one or more battery cells 36 connected in series and / or in parallel with the terminals of the second battery module 24B.

[0085] In some embodiments, the battery system 12 can include multiple battery modules 24 to facilitate operational compatibility with multiple voltage domains. For example, in the depicted embodiment, the first battery module 24A can operate (e.g., receive and / or supply) power in a first (e.g., high or 48 volt) voltage domain. On the other hand, the second battery module 24B can operate (e.g., receive and / or supply) power in a second (e.g., low or 12 volt) voltage domain.

[0086] Additionally or alternatively, in some embodiments, the battery system 12 may include multiple battery modules 24 to increase implementation flexibility and / or ease of implementation. For example, while the first battery module 24A and the second battery module 24B are connected in series, a single battery module 24 may be used instead. However, such a battery module 24 may be large, heavy, and / or generate a high voltage at its terminals, thereby limiting the ease with which the battery module 24 can be moved. Furthermore, such a battery module 24 may limit implementation flexibility, for example, in another battery system 12 in which the first battery module 24A and the second battery module 24B are connected in parallel instead.

[0087] In contrast, Figure 4 A second battery system 12B is shown for use in a different application, such as a stationary power system. As depicted, in addition to a first battery module 24A and a second battery module 24B, the second battery system 12B also includes a plurality of battery modules 24. Specifically, the depicted battery system 12 includes a plurality of battery chains 44, each battery chain including a plurality of battery modules 24 connected in series and in parallel between a positive bus 47 and a negative bus 49. For example, a first battery chain 44A includes N battery modules 24 connected in series. In some embodiments, each battery module 24 can be intended to be electrically identical, and thus each battery chain 44 can include the same number of battery modules 24.

[0088] Due at least in part to the different number of battery modules 24, the battery control system 26 used in the first battery system 12A and the battery control system 26 used in the second battery system 12B may be different. For example, instead of coordinating the operation of only the first battery module 24A and the second battery module 24B, the battery control system 26 in the second battery system 12B may coordinate the operation of multiple battery chains 44. In other words, different battery control systems 26 may perform different control functions—particularly when used for different applications.

[0089] To help explain the different control functions, the battery control system 26 can be implemented at least in part based on a battery control system architecture. Generally, multiple different battery control system architectures can be capable of implementing the battery control system 26. However, the multiple different battery control system architectures may have different impacts on implementation flexibility and / or implementation-related costs.

[0090] For example, the battery system 12 may be implemented using a purely centralized battery control system architecture designed specifically for the battery control system 26. Because it is designed specifically for the battery system 12, the purely centralized battery control system architecture can reduce the amount of redundant infrastructure, thereby reducing implementation-related costs. However, the purely centralized battery control system architecture is generally unique to the battery control system 26, thereby limiting implementation flexibility (e.g., the number of compatible battery system variants).

[0091] At the other extreme, the battery control system 26 can be implemented using a purely distributed battery control system architecture, which provides basic building blocks for every potential control function that can be implemented in the battery system 12. In this way, the building blocks in the purely distributed battery control system architecture can be used to implement a wide variety of battery control systems 26, thereby increasing implementation flexibility. However, a purely distributed battery control system architecture may result in an increased amount of redundant infrastructure. For example, because each building block can communicate with another building block, the increased number of building blocks may increase the communication infrastructure (e.g., communication interfaces and / or buses) used to implement the battery control system 26, thereby increasing implementation-related costs.

[0092] Leveraging the advantages of both extremes, in some embodiments, a hybrid battery control system architecture can be used to implement a battery control system 26 with increased implementation flexibility and / or reduced implementation-related costs. Specifically, the hybrid battery control system architecture can provide basic building blocks that each provide a different level of control (e.g., abstraction or granularity). For example, a basic building block can include a battery cell control unit 46 that provides battery module-level and / or battery cell-level control functionality. Additionally, a basic building block can include a system control unit 48 that provides battery system-level control functionality.

[0093] In addition, the basic building block may include a string control unit 50 that provides battery string-level control functionality. As used herein, a battery string is intended to describe one or more battery modules 24 connected in series. Thus, a battery chain 44 may include one or more battery strings 52. In some embodiments, the battery chain 44 may be divided into multiple battery strings 52 to facilitate maintaining control granularity without significantly increasing control complexity. For example, in the depicted embodiment, the battery chain 44 is divided into three strings of M battery modules 24, namely a first battery string 52A, a second battery string 52B, and a third battery string 52C.

[0094] Furthermore, the hybrid battery control system architecture may provide the infrastructure for each building block. For example, the hybrid battery control system architecture may specify the processing infrastructure, power infrastructure, and / or communication infrastructure included in each of the cell control unit 46, the system control unit 48, and the string control unit 50. In some embodiments, the processing infrastructure may indicate one or more processor units, processing circuitry, and / or logic circuitry used in the building block. Additionally, the communication infrastructure may indicate one or more communication interfaces used in the building block.

[0095] In addition, the power infrastructure may indicate one or more isolation barriers 56 used in the building blocks and / or their target operating voltage domains. As described above, the battery system 12 may operate in multiple different voltage domains. For example, in the depicted embodiment, the battery module 24 may operate in a high voltage domain. Thus, the battery module 24 may be used as a high voltage power supply to supply power to electrical components designed to operate using power in the high voltage domain, which may include a portion of the battery control system 26. However, another portion of the battery control system 26 may be designed to operate using power in a low voltage domain and therefore receive power from a low (e.g., external) voltage power supply 54.

[0096] Because different parts operate in different voltage domains, the battery control system 26 may include one or more isolation barriers 56. Specifically, the isolation barrier 56 can electrically isolate electrical components operating in a first (e.g., high) voltage domain from electrical components operating in a second (e.g., low) voltage domain. Additionally, in some embodiments, the isolation barrier 56 can electrically isolate the battery system 12 from a common ground (e.g., system ground) such as a vehicle chassis or a device housing.

[0097] In this manner, the battery control system 26 may be implemented using building blocks specified in the hybrid battery control system architecture, for example, based at least in part on the target functionality to be provided by the battery control system 26 and the functionality provided by each building block. However, in some cases, it may be desirable to enable multiple different hybrid battery control system architectures to implement the battery control system 26. Furthermore, in some cases, the multiple different hybrid battery control system architectures may each have a different impact on implementation flexibility and / or implementation-related costs.

[0098] In other words, determining an appropriate hybrid battery control system architecture can be a complex process. Therefore, in some embodiments, a design system can be used to facilitate determining a hybrid battery control system architecture for implementing the battery control system 26, such as by selecting the hybrid battery control system architecture from a plurality of candidates based on various factors.

[0099] Design system for hybrid battery control system architecture

[0100] To help illustrate, Figure 5 1 shows one embodiment of a design system 58 that can be used to determine a hybrid battery control system architecture. In the depicted embodiment, the design system 58 is communicatively coupled to one or more battery systems 12, a communication network 60, one or more input devices 62, and one or more output devices 64. It should be understood that the depicted embodiment is merely intended to illustrate components that can be communicatively coupled to the design system 58. For example, in other embodiments, the design system 58 can be communicatively coupled to any combination of the battery systems 12, the communication network 60, the input devices 62, and the output devices 64.

[0101] In any case, the communication network 60, input device 62, and / or output device 64 can facilitate communications to and / or from the design system 58. For example, the communication network 60 can enable the design system 58 to communicate with other electronic devices. Thus, in some embodiments, the communication network 60 can be a personal area network (PAN) such as a Bluetooth network, a local area network (LAN) such as an 802.11x Wi-Fi network, a wide area network (WAN) such as a 4G or LTE cellular network, a controller area network (CAN), and / or a local interconnect network (LIN).

[0102] Additionally, input device 62 can facilitate user interaction with design system 58, for example, by receiving user input. Thus, in some embodiments, input device 62 can include buttons, a keyboard, a mouse, a trackpad, and / or the like. Additionally, output device 62 can facilitate user interaction with design system 58, for example, by indicating determined information. Thus, in some embodiments, output device 64 can include an electronic display, a speaker, and / or the like.

[0103] To facilitate determining the hybrid battery control system architecture, the design system may include a design processor 68 and a design memory 70. In some embodiments, the design memory 70 may include a tangible, non-transitory computer-readable medium storing instructions executable by the design processor 68. Thus, in such embodiments, the design memory 70 may include random access memory (RAM), read-only memory (ROM), rewritable non-volatile memory (e.g., flash memory), a hard drive, an optical disk, etc. Additionally, the design processor 68 may include one or more general-purpose processing units, processing circuitry, and / or logic circuitry. For example, the design processor 68 may include one or more microprocessors, one or more application-specific integrated circuits (ASICs), and / or one or more field-programmable logic arrays (FPGAs).

[0104] As described above, the design system 58 can determine a hybrid battery control system architecture by selecting from a plurality of candidates based on various factors, such as implementation flexibility and / or implementation-related costs. In some embodiments, the design system 58 can analyze the plurality of candidates based at least in part on an objective function 72. Specifically, the objective function 72 can indicate a metric that takes into account the candidate's expected ability to implement the various factors. Thus, in some embodiments, the design system 58 can store the objective function 72 in the design memory 70, receive the objective function via the input device 62, and / or receive the objective function via the communication network 60. Additionally, in some embodiments, the design system 58 can indicate the determined hybrid battery control system via the output device 64 and / or the communication network 60 to facilitate implementation of the battery control system 26 using the hybrid battery control system.

[0105] Furthermore, in some embodiments, the design system 58 may receive one or more of the candidates via the communication network 60 and / or the input device 62. Additionally or alternatively, the design system 58 may determine one or more of the candidates by analyzing one or more battery systems 12 and / or battery control systems 26 with which the hybrid battery control system architecture is intended to be compatible. For example, in some embodiments, the design system 58 may determine the candidates based at least in part on a target control level that may be implemented in the battery control system 26, target functionality to be provided by the battery control system 26, and / or an infrastructure for implementing the respective target functionality.

[0106] To help illustrate, Figure 6 One embodiment of a process 74 for determining a hybrid battery control system architecture is described in

[15] . Generally speaking, process 74 includes determining a target control level in the battery control system (process block 76), determining target functions of the battery control system (process block 78), determining an infrastructure for implementing each of the target functions (process block 80), and partitioning the target functions among the control levels (process block 82). In some embodiments, process 74 can be implemented by executing instructions stored in a tangible, non-transitory computer-readable medium such as design memory 70 using a processor such as design processor 68.

[0107] Accordingly, in some embodiments, the design system 58 can determine target control levels in the battery control system 26 that are intended to be implemented using the hybrid battery control system architecture (process block 76) and determine target functionality to be provided at each target control level (process block 78). In some embodiments, the design system 58 can receive the target control levels and / or target functionality from the communication network 60 and / or input device 62, for example, based on manual user input. Additionally or alternatively, to facilitate determining the target control levels and / or target functionality, the design system 58 can analyze the battery system 12 in which the battery control system 26 is used. By analyzing the battery system 12, the design system 58 can determine an implementation (e.g., a hierarchical organization) of the battery system 12.

[0108] For example, by analyzing Figure 4 For the second battery system 12B, the design system 58 may determine the number and / or target operating parameters of the battery cells 36, battery modules 24, battery strings 52, and / or battery chains 44 in the second battery system 12B. Specifically, the design system 58 may determine that the second battery system 12B is implemented with battery modules 24 that each include a specific number (e.g., four or sixteen) of battery cells 36. Additionally, the design system 58 may determine that the second battery system 12B is implemented with a specific number (e.g., three) of battery strings 52 per battery chain 44.

[0109] Based at least in part on the implementation of the battery system 12, the design system 58 may determine the control levels that may be used in the battery control system 26 of the battery system 12. For example, Figure 4 For the second battery system 12B, the design system 58 can determine whether the battery control system 26 can provide a cell control level, a module control level, a string control level, and / or a system control level. In addition, based at least in part on the implementation of the battery system 12, the design system 58 can determine the target functionality to be provided at each control level.

[0110] To help illustrate, Figure 7 One embodiment of a process 84 for determining target functionality at different control levels is described in

[0026] . In general, process 84 includes determining target cell-level functionality (process block 86), determining target module-level functionality (process block 88), determining string-level functionality (process block 90), and determining system-level functionality (process block 92). In some embodiments, process 84 may be implemented by executing instructions stored in a tangible, non-transitory, computer-readable medium such as design memory 70 using a processor such as design processor 68.

[0111] Accordingly, in some embodiments, the design system 58 may determine target cell-level functions (process block 86). Specifically, the design system 58 may determine control functions that the battery control system 26 may wish to employ to control the operation of the battery cells 36 in the battery system 12. In some embodiments, the control functions employed by the battery control system 26 may depend on the implementation of the battery cells 36 in the battery system 12, such as the number of battery cells 36 in the battery system 12, the number of battery cells 36 per battery module 24, the electrical connections of the battery cells 36 in the battery modules 24, the target operating voltage of the battery cells 36, the target operating current of the battery cells 36, the power rating of the battery cells 36, the storage capacity of the battery cells 36, and / or the target operating temperature of the battery cells 36.

[0112] Therefore, based at least in part on the implementation of the battery cell, the design system 58 can determine target cell-level functionality. In some embodiments, the design system 58 can determine that the target cell-level functionality includes determining an operating parameter (e.g., voltage) of the battery cell 36, such as for detecting a fault in the battery cell 36. The design system 58 can also determine that the target cell-level functionality includes providing control commands, such as for disconnecting the battery cell 36 when a fault is detected in the battery cell 36, for controlling the supply of power to the battery cell 36 (e.g., charging), and / or for controlling the supply of power from the battery cell 36 (e.g., discharging).

[0113] Additionally, the design system 58 may determine target module-level functionality (process block 88). Specifically, the design system 58 may determine control functionality that the battery control system 26 may wish to employ to control the operation of the battery modules 24 in the battery system 12. In some embodiments, the control functionality employed by the battery control system 26 may depend on the implementation of the battery modules 24 in the battery system 12, such as the number of battery modules 24 in the battery system 12, the number of battery modules 24 in each battery string 52, the number of battery modules 24 in each battery chain 44, the target operating voltage of the battery modules 24, the power rating of the battery modules 24, the storage capacity of the battery modules 24, and / or the target operating temperature of the battery modules 24.

[0114] Thus, based at least in part on the implementation of the battery module, the design system 58 can determine a target module-level functionality. In some embodiments, the design system 58 can determine that the target module-level functionality includes determining an operating parameter (e.g., voltage) of the battery module 24, such as for detecting a fault in the battery module 24. Additionally, the design system 58 can determine that the target module-level functionality includes coordinating the operation of the plurality of battery cells 36 in the battery module 24, such as so that the plurality of battery cells 36 operate at substantially the same voltage and / or substantially the same current. Furthermore, the design system 58 can determine that the target module-level functionality includes providing control commands, such as for disconnecting the battery module 24 when a fault is detected in the battery module 24, for controlling the supply of power to the battery module 24 (e.g., charging), and / or for controlling the supply of power from the battery module 24 (e.g., discharging).

[0115] Additionally, the design system 58 may determine target string-level functions (process block 90). Specifically, the design system 58 may determine control functions that the battery control system 26 may wish to employ to control the operation of the battery strings 52 in the battery system 12. In some embodiments, the control functions employed by the battery control system 26 may depend on the implementation of the battery strings 52 in the battery system 12, such as the number of battery strings 52 in the battery system 12, the number of battery strings 52 per battery chain 44, the target operating voltage of the battery strings 52, and / or the target operating current of the battery strings 52.

[0116] Therefore, based at least in part on the implementation of the battery string, the design system 58 can determine a target string-level function. In some embodiments, the design system 58 can determine that the target string-level function includes determining an operating parameter (e.g., voltage) of the battery string 52, such as for detecting a fault in the battery string 52. Additionally, the design system 58 can determine that the target module-level function includes coordinating the operation of the battery modules 24 in the battery string 52, such as causing the plurality of battery modules 24 to operate at substantially the same voltage and / or substantially the same current. Furthermore, the design system 58 can determine that the target string-level function includes providing control commands, such as for disconnecting the battery string 52 when a fault is detected in the battery string 52, for controlling the supply of power to the battery string 52 (e.g., charging), and / or for controlling the supply of power from the battery string 52 (e.g., discharging).

[0117] The design system 58 may also determine target system-level functionality (process block 92). Specifically, the design system 58 may determine control functions that the battery control system 26 may wish to employ to control the operation of the battery system 12. In some embodiments, the control functions employed by the battery control system 26 may depend on the implementation of the battery system 12, such as the target operating voltage of the battery system 12 and / or the target operating current of the battery system 12.

[0118] Thus, based at least in part on the implementation of the battery system, the design system 58 can determine a target system-level function. In some embodiments, the design system 58 can determine that the target system-level function includes determining an operating parameter (e.g., voltage) of the battery system 12, such as for detecting a fault in the battery system 12. Additionally, the design system 58 can determine that the target system-level function includes coordinating the operation of multiple battery strings 52 in the battery system, such as so that the multiple battery strings 52 operate at approximately the same voltage and / or approximately the same current. Furthermore, the design system 58 can determine that the target string-level function includes providing control commands, such as for disconnecting the battery system 12 when a fault is detected in the battery system 12, for controlling the supply of power to the battery system 12 (e.g., charging), and / or for controlling the supply of power from the battery system 12 (e.g., discharging).

[0119] In this manner, the design system 58 can determine the target functionality of the battery control system 26. As described above, in some embodiments, the target functionality can be determined at a plurality of different control levels, such as to determine a target cell-level functionality, a target module-level functionality, a target string-level functionality, and / or a target system-level functionality. It should be understood that the target functionality can be determined for any number of control levels. For example, in some embodiments, the target functionality can include a target string-level functionality. Furthermore, in some embodiments, the target functionality can be determined at a single control level, particularly in less complex battery systems 12, such as those having a smaller number of battery modules 24.

[0120] Return to Figure 6 In process 74, the design system 58 may determine the infrastructure expected to be used in the battery system 12 to implement each of the target functions (process block 80). In some embodiments, to facilitate implementation of the target functions, the battery control system 26 may communicate data, process data, and / or utilize power. Thus, in some embodiments, the design system 58 may determine the communication infrastructure, processing infrastructure, and / or power infrastructure expected to be used to implement the target functions.

[0121] To help illustrate, Figure 8 One embodiment of a process 94 for determining the infrastructure expected to be used to implement a target function is described in

[15] . Generally speaking, process 94 includes determining a processing infrastructure for implementing the target function (process block 96), determining a communication infrastructure for implementing the target function (process block 98), and determining a power infrastructure for implementing the target function (process block 100). In some embodiments, process 94 can be implemented by executing instructions stored in a tangible, non-transitory computer-readable medium such as design memory 70 using a processor such as design processor 68.

[0122] Accordingly, in some embodiments, the design system 58 may determine the processing infrastructure expected to be used to implement the target functionality (process block 96). In some embodiments, the battery control system 26 may utilize different types of processing infrastructure, such as analog-to-digital converters (ADCs), logic circuitry, processor units, and / or processing circuitry, to process and / or analyze data for control operations. Thus, in some embodiments, the design system 58 may determine the amount and / or type of processing infrastructure expected to be used to implement the target functionality.

[0123] Additionally, the design system 58 may determine the communication infrastructure expected to be used to implement the target functionality (process block 98). In some embodiments, the battery control system 26 may utilize different types of communication infrastructure, such as a serial communication interface, a parallel communication interface, a serial communication bus, and / or a parallel communication bus, to communicate data externally and / or internally between different components. Thus, in some embodiments, the design system 58 may determine the number and / or type of communication infrastructure expected to be used to implement the target functionality.

[0124] In addition, the design system 58 may determine the power infrastructure expected to be used to implement the target functionality (process block 100). In some embodiments, the battery control system 26 may consume power to facilitate processing and / or communicating data. Thus, in some embodiments, the design system 58 may determine the target operating voltage (e.g., voltage domain) for components in the battery control system 26 (process block 102) and determine the power sources expected to be used to supply power at the target operating voltage (process block 106).

[0125] As described above, in some embodiments, different portions of the battery control system 26 may operate in different voltage domains and, therefore, may include an isolation barrier 56 therebetween. Accordingly, in some embodiments, the design system 58 may determine whether the portions of the battery control system 26 that are intended to implement the target function operate in different voltage domains and determine whether the isolation barrier 56 is intended to implement the target function based at least in part on whether the portions of the battery control system 26 that are intended to implement the target function operate in different voltage domains.

[0126] In this way, the design system 58 can determine the infrastructure of the battery control system 26 that is expected to be used to implement one or more target functions. As described above, in some embodiments, the target functions can be implemented using processing infrastructure, communication infrastructure, and / or power infrastructure. It should be understood that in other embodiments, other types of infrastructure can be used to implement the target functions in addition or alternatively and are therefore determined by the design system. For example, in some embodiments, the infrastructure for implementing the target functions may include other physical infrastructure, such as spacing infrastructure, packaging infrastructure, and / or switch (e.g., relays, contactors, and / or circuit breakers) infrastructure.

[0127] Return Figure 6 During process 74, the design system 58 may determine the hybrid battery control system architecture by assigning target functions and associated infrastructure to building blocks (process block 82). Specifically, the design system 58 may determine which target function to assign to the building block. As described above, the target function may be implemented using infrastructure in the building block, thereby affecting implementation-related costs, such as the size of the building block, the packaging of the building block (e.g., within a battery module), the number of components, operating power consumption, and / or component cost. Additionally, providing the target function may increase the number of different battery control systems 26 that can be implemented, thereby affecting implementation flexibility.

[0128] Therefore, to determine which target functions to provide, the design system 58 can evaluate the impact that providing each target function is expected to have on implementation flexibility and / or implementation-related costs. In some embodiments, to facilitate balancing the expected impacts, the design system 58 can utilize an objective function 72. For example, based on the objective function 72, the design system 58 can exclude target functions that are expected to be used in fewer battery control systems 26 because the increase in implementation-related costs (particularly in battery control systems 26 that do not utilize the target functions) may outweigh the increased implementation flexibility resulting from providing the target functions. On the other hand, based on the objective function 72, the design system can specify target functions that are expected to be used in more battery control systems 26 because the increased implementation flexibility may outweigh the increased implementation-related costs resulting from providing the target functions.

[0129] In some cases, multiple target functions may at least partially overlap. For example, a function for determining the current flowing through a battery string 52 may also indicate the current flowing through a battery module 24 within the battery string 52. Furthermore, a function for commanding a relay to disconnect a battery string 52 may also disconnect a battery module within the battery string 52. Furthermore, a function for determining the voltage across a battery module 24 may at least provide an indication of the voltage across a battery cell 36 within the battery module 24.

[0130] Therefore, in some embodiments, the design system 58 can determine at least partially overlapping target functions to be allocated. In this way, to facilitate reducing implementation-related costs, the design system 58 can determine a hybrid battery control system architecture such that some target functions, along with associated infrastructure, are centralized into fewer (e.g., one) building blocks. Specifically, centralizing some target functions can facilitate reducing the amount of redundant infrastructure used to implement the battery control system 26, thereby reducing implementation-related costs.

[0131] In addition, the design system 58 can determine a hybrid battery control system architecture such that some target functions are distributed across multiple building blocks along with the associated infrastructure. In some cases, the target functions provided by each building block may affect implementation flexibility. For example, when both the string control unit 50 and the cell control unit 46 are capable of providing the target functions, the battery system 26 can implement the target functions using the string control unit 50, the cell control unit 46, or both the string control unit 50 and the cell control unit 46. Therefore, distributing some target functions can facilitate increasing the number of compatible battery control systems 26 (e.g., with varying target control levels), thereby increasing implementation flexibility.

[0132] Accordingly, to facilitate the decision of whether to centralize or distribute target functionality, the design system 58 may determine the expected impact of the centralized and distributed objectives on implementation flexibility and / or implementation-related costs. In some embodiments, to facilitate balancing the expected impacts, the design system 58 may utilize an objective function 72. For example, based on the objective function 72, the design system 58 may centralize computationally intensive functionality within the string control unit 50, thereby facilitating a reduction in processing infrastructure within the cell control unit 46, a reduction in processing infrastructure within the system control unit 48, and / or a reduction in communication infrastructure implemented within the battery control system 26. Additionally, based on the objective function 72, the design system 58 may centralize communication functionality for facilitating communication between electrical components operating in different voltage domains within the string control unit 50, thereby facilitating a reduction in the number of isolation barriers 56 within the cell control unit 46 and / or the system control unit 48.

[0133] Furthermore, based on the objective function 72, the design system 58 may centralize communication functionality for facilitating communication with external components within the system control unit 48, thereby facilitating a reduction in the amount of communication infrastructure within the cell control unit 46 and / or the string control unit 50. Furthermore, based on the objective function 72, the design system 58 may centralize functionality for determining some operating parameters. For example, centralizing current determination functionality within the string control unit 50 may eliminate communication infrastructure that might otherwise be used to communicate current from the cell control unit 46 to the string control unit 50.

[0134] On the other hand, based on the objective function 72, the design system 58 can distribute less computationally complex functions to different control levels to facilitate improved control granularity. For example, the design system 58 can distribute the voltage determination function to the cell control unit 46 and the string control unit 50, thereby enabling the battery control system 26 to make determinations at any combination of multiple different control levels. In this way, the design system 58 can determine a hybrid battery control system architecture that enables implementation of a battery control system 26 with different control levels. For example, the hybrid battery control system architecture can be enabled to implement a battery control system 26 with only a system control level, as well as a battery control system 26 with a module control level, a string control level, and a system control level.

[0135] Furthermore, in some embodiments, providing multiple control levels can facilitate improved operation of the battery control system 26. In some embodiments, this can facilitate improved diagnostics, for example by enabling the battery control system 26 to better localize the cause of a fault. For example, when a fault is detected in a battery string 52, by determining operating parameters at the module control level, the battery control system 26 can identify a specific battery module 24 as the cause of the fault, thereby enabling replacement of the specific battery module 24 rather than the entire battery string 52.

[0136] In this manner, utilizing the techniques described above, the design system 58 can determine a hybrid battery control system architecture that increases the implementation flexibility of the battery control system 26 and / or reduces its implementation-related costs. In some embodiments, implementation flexibility and implementation-related costs may be inversely correlated. Therefore, by utilizing the objective function 72, the design system 58 can find a target balance between the expected impact on implementation flexibility and the expected impact on implementation-related costs. In fact, in some embodiments, the design system 58 can adjust the objective function 72 to facilitate determining hybrid battery control system architectures that find different target balances between implementation-related costs and implementation flexibility. In other words, the design system 58 may be able to determine multiple different hybrid battery control system architectures that produce different balances between implementation flexibility and implementation-related costs. To assist in illustration, some exemplary hybrid battery control system architectures are described below.

[0137] Exemplary Hybrid Battery Control System Architecture

[0138] Figure 9An example of a hybrid battery control system architecture for implementing the battery control system 26 in the second battery system 12B is shown in FIG. As depicted, the second battery system 12B includes a low-voltage power source 54 and battery modules 24 (e.g., a high-voltage power source), each of which includes battery cells 36. Additionally, the second battery system 12B includes battery chains 44 connected in parallel between a positive bus 47 and a negative bus 49, each of which includes battery modules 24 connected in series and organized into battery strings 52.

[0139] Furthermore, the battery control system 26 is implemented using a cell control unit 46, a string control unit 50, and a system control unit 48 provided by a hybrid battery control system architecture. As described above, the hybrid battery control system architecture may dictate system-level functionality to be provided by the system control unit 48. For example, the system-level functionality may include centralizing communications between the battery control system 26 and external components such as the supervisory control system 18. Additionally, the system-level functionality may include coordinating the operation of the battery strings 52 in the battery system 12 and / or supplying power to the string control unit 50.

[0140] Thus, in some embodiments, the system-level functional control unit 48 can be electrically coupled to the low-voltage power supply 54, thereby enabling the system control unit 48 to receive power. Additionally, in some embodiments, the system control unit 48 can be electrically coupled to the string control unit 50, thereby enabling the system control unit 48 to supply power to the string control unit 50. Furthermore, in some embodiments, the system control unit 48 can be communicatively coupled to the string control unit 50, thereby enabling the system control unit 48 to pass instructions (e.g., control commands) to the string control unit 50. To enable the provision of system-level functions, as described above, the hybrid battery control system architecture can indicate the infrastructure used in the system control unit 48.

[0141] To help illustrate, Figure 10 1 shows one embodiment of a system control unit 48 (e.g., a building block) that may be specified by a hybrid battery control system architecture. As depicted, the system control unit 48 includes a parallel communication interface 110, a serial communication interface 112, a processing unit 114, a memory 116, an external communication interface 118, and a system relay communication interface 120. It should be understood that the components described are intended to be illustrative only. In other words, in actual implementations, the system control unit 48 may include additional and / or fewer components.

[0142] With respect to the depicted embodiment, the processing infrastructure in the system control unit 48 includes a processing unit 114 that executes instructions stored in a memory 116 to provide system-level functionality. Thus, in some embodiments, the processing unit 114 may include one or more microprocessors, and the memory 116 may include a tangible, non-transitory, computer-readable medium storing instructions executable by the processing unit 114. Thus, in such embodiments, the memory 116 may include random access memory (RAM), read-only memory (ROM), rewritable non-volatile memory (e.g., flash memory), a hard drive, an optical disk, etc.

[0143] As described above, the system control unit 48 can coordinate the operation of the battery system 12. To facilitate the coordinated operation, the processing unit 114 can process and / or analyze operating parameters related to the operation of the battery system 12 (process block 122). In addition, as described above, the system control unit 48 can centralize external communications originating from the battery control system 26. To facilitate providing external communications, the processing unit 114 can generate external communication data and / or process received external communication data (process block 124).

[0144] Thus, to facilitate providing centralized external communication functionality, the communication infrastructure includes an external communication interface 118. In some embodiments, the external communication interface 118 can be communicatively coupled to an external communication network, thereby enabling the system control unit 48 to transmit and / or receive data communicated with external components via the external communication network. Additionally, to facilitate providing battery system coordination functionality, the communication infrastructure includes a parallel communication interface 110 and / or a serial communication interface 112. In some embodiments, the parallel communication interface 110 can be communicatively coupled to a parallel communication network such as a controller area network (CAN), and the serial communication interface 112 can be communicatively coupled to a serial communication network such as a ripcord network. In this manner, the parallel communication interface 110 and / or the serial communication interface 112 can enable the system control unit 48 to transmit instructions to the string control unit 50 and / or receive operating parameters from the string control unit.

[0145] Additionally, the communication infrastructure may include a system relay communication interface 120. In some embodiments, the system relay communication interface 120 may be communicatively coupled to, for example, a system relay that closes to connect the battery system 12 to the electrical load 16 and opens to disconnect the battery system from the electrical load 16. In this manner, the system relay communication interface 120 may enable the system control unit 48 to connect or disconnect the battery system, for example, based at least in part on an analysis of received battery system operating parameters. In this manner, the hybrid battery control system architecture may provide a system control unit 48 building block and associated infrastructure for providing various system-level functions.

[0146] Return to Figure 9 As shown in the second battery system 12B, as described above, the hybrid battery control system architecture may indicate string-level functions to be provided by each string control unit 50. For example, the string-level functions may include coordinating the operation of the battery modules 24 in the respective battery strings 52. Additionally, the string-level functions may include centralizing communications from the respective battery strings 52 to the system control unit 48. Furthermore, the string-level functions may include providing computationally complex functions at the string control level.

[0147] Thus, in some embodiments, the string control unit 50 can be communicatively coupled to each cell control unit 46 of the battery modules 24 in a corresponding battery string 52. For example, in the depicted embodiment, the first string control unit 50A can be communicatively coupled to the cell control unit 46 corresponding to the battery module 24 in the first battery string 52A, the second string control unit 50B can be communicatively coupled to the cell control unit 46 corresponding to the battery module 24 in the second battery string 52B, and the third string control unit 50L can be communicatively coupled to the cell control unit 46 corresponding to the battery module 24 in the third battery string 52C. In this manner, the string control unit 50 can determine string-level operating parameters based at least in part on the cell-level operating parameters and / or module-level operating parameters received from the cell control units 46.

[0148] Additionally, in some embodiments, the string control unit 50 can be electrically coupled to the cell control unit 46 and / or one or more of the battery modules 24, thereby enabling the string control unit 50 to receive high voltage power. In this manner, the string control unit 50 can determine additional string-level operating parameters, such as string current and / or string voltage.

[0149] Furthermore, as described above, the string control unit 50 can receive low-voltage power from the system control unit 48. To facilitate reducing the impact of the operation of the battery control system 26 on the operation of the battery system 12, the string control unit 50 can generally operate using the low-voltage power received from the system control unit 48, for example, by boosting the power to high-voltage power. However, since it also receives high-voltage power from the battery modules 24, the string control unit 50 can switch to using high-voltage power, for example, when the supply of low-voltage power is interrupted. To enable the provision of string-level functionality, as described above, the hybrid battery control system architecture can dictate the infrastructure used in each string control unit 50.

[0150] To help illustrate, Figure 11FIGURE 5 illustrates one embodiment of a string control unit 50 that may be specified by a hybrid battery control system architecture. As depicted, string control unit 50 includes a parallel communication interface 126, a serial communication interface 128, processing circuitry 130, a processing unit 132, memory 134, a string relay communication interface 136, and isolation barrier 56. It should be understood that the components described are intended to be illustrative only. In other words, in actual implementations, string control unit 50 may include additional and / or fewer components.

[0151] With respect to the depicted embodiment, the processing infrastructure in string control unit 50 includes processing circuitry 130 and processing unit 132. In some embodiments, processing circuitry 130 and processing unit 132 may provide at least partially overlapping string-level functionality to improve the reliability of string control unit 50, particularly because computationally more complex functions may be centralized within string control unit 50. In addition to utilizing only two different types of processing infrastructure, operational reliability may be improved at least in part due to the different operating principles of processing circuitry 130 and processing unit 132. Specifically, processing circuitry 130 may operate based on programmable circuit connections formed within processing circuitry 130 and, therefore, may include one or more field programmable gate arrays (FPGAs).

[0152] On the other hand, the processing unit 132 can operate by executing instructions stored in the memory 134. Thus, in some embodiments, the processing unit 132 may include one or more microprocessors, and the memory 134 may include a tangible, non-transitory computer-readable medium storing instructions executable by the processing unit 132. Thus, in such embodiments, the memory 134 may include a random access memory (RAM), a read-only memory (ROM), a rewritable non-volatile memory (e.g., flash memory), a hard drive, an optical disk, etc. In this way, the possibility of interference that simultaneously affects the operation of both the processing circuit system 130 and the processing unit 132 can be reduced, thereby improving the operational reliability of the string control unit 50.

[0153] As described above, the string control unit 50 may coordinate the operation of the battery modules 24 in the respective battery strings 52. To facilitate the coordinated operation, the processing unit 132 and / or the processing circuitry 130 may process and / or analyze operating parameters related to the operation of the battery modules 24 in the battery strings 52 (process block 138).

[0154] Therefore, to facilitate providing battery module 24 coordination functionality, the communication infrastructure includes a parallel communication interface 126 and / or a serial communication interface 128. In some embodiments, the parallel communication interface 126 can be communicatively coupled to a parallel communication network, such as a controller area network (CAN), and the serial communication interface 128 can be communicatively coupled to a serial communication network, such as a ripcord network. In this manner, the parallel communication interface 110 and / or the serial communication interface 112 can enable the string control unit 50 to receive cell-level and / or module-level operating parameters from the cell control unit 50 and / or transmit instructions to the cell control unit 50. Additionally, the parallel communication interface 110 and / or the serial communication interface 112 can enable the string control unit 50 to receive instructions (e.g., control commands) from the system control unit 48 and / or transmit string-level operating parameters to the system control unit 48 and / or another string control unit 50.

[0155] Furthermore, to enable communication with components operating in different voltage domains, the serial communication interface 112 may include a low-voltage serial communication interface communicatively coupled to a low-voltage serial communication network, and / or a high-voltage serial communication interface communicatively coupled to a high-voltage serial communication network. In this manner, in some embodiments, the low-voltage serial communication interface may communicatively couple the string control unit 50 to the system control unit 48 and / or another string control unit 50 via the low-voltage serial communication network. Additionally, in some embodiments, the high-voltage serial communication interface may communicatively couple the string control unit 50 to one or more battery cell control units 48 via the high-voltage serial communication network. Similarly, in some embodiments, the parallel communication interface 110 may include a low-voltage parallel communication interface communicatively coupled to a low-voltage parallel communication network, and / or a high-voltage parallel communication interface communicatively coupled to a high-voltage parallel communication network.

[0156] In addition, because the string control unit 50 receives high voltage power from the battery module 24 and low voltage power from the low voltage power source 54, the power infrastructure includes an isolation barrier 56. As described above, the isolation barrier 56 can facilitate electrically isolating electrical components operating in the high voltage domain from electrical components operating in the low voltage domain. In some embodiments, the number of isolation barriers 56 may substantially impact implementation-related costs compared to other components such as communication interfaces. Therefore, the hybrid battery control system architecture can centralize the implementation of the isolation barrier 56 on a per-battery string 52 basis, thereby facilitating a reduction in implementation-related costs. In this way, the hybrid battery control system architecture can provide the string control unit 50 building blocks as well as the infrastructure for providing various string-level functions.

[0157] With respect to the depicted embodiment, the communication infrastructure of the string control unit 50 also includes a string relay communication interface 136. In some embodiments, the string relay communication interface 136 can be communicatively coupled to a string relay that can be controlled to selectively electrically connect the battery string 52 to the battery system 12 and / or an electrical load. For example, the string relay communication interface 136 can enable the string control unit 50 to transmit a control command instructing the string relay to open to electrically disconnect the battery string 52 from the battery system 12. Additionally, the string communication interface 136 can enable the string control unit 50 to transmit a control command instructing the string relay to close to electrically connect the battery string 52 to the battery system 12.

[0158] As described above, in some embodiments, multiple battery strings 52 can be connected in series, for example as a battery chain 44, wherein each battery string 52 uses a corresponding string control unit 50. In such embodiments, operating a string relay can selectively connect or disconnect multiple battery strings 52. Therefore, in such embodiments, the string relay can be communicatively coupled to the string communication interface 136 of one (e.g., master) string control unit 50, thereby enabling the one string control unit 50 to transmit control commands to the string relay. In this manner, the string communication interface 136 of other (e.g., slave) string control units 50 can be communicatively coupled to other electrical components, such as a fan.

[0159] Return to Figure 9 As shown in the second battery system 12B, as described above, the hybrid battery control system architecture can indicate the cell-level functions and / or module-level functions to be provided by each battery cell control unit 46. In addition, in some embodiments, the battery cell control unit 46 can be physically coupled to the corresponding battery module 24. For example, the first battery cell control unit 46A can be physically coupled to the first battery module 24A. In fact, in some embodiments, the battery cell control unit 46 can be arranged on or within the housing of the corresponding battery module 24. In addition, in some embodiments, the battery cell control unit 46 can be electrically coupled to the terminals of the corresponding battery module 24, thereby enabling the battery cell control unit 46 to receive power for performing the battery cell-level functions and / or module-level functions.

[0160] To facilitate coupling with and / or receiving power from the battery modules 24, the hybrid battery control system architecture can assign computationally less complex cell-level functions and / or module-level functions to the cell control units 46. As described above, in some embodiments, the cell-level functions can include determining operating parameters related to the operation of the battery cells 36. For example, each cell control unit 46 can determine operating parameters of its corresponding battery module 24 and operating parameters of the battery cells 36 in the battery module 24. In the depicted embodiment, the first cell control unit 46A can determine the voltage of the first battery module 24A, the voltage of the first (e.g., top) group of battery cells 36 in the first battery module 24A, the voltage of the second (e.g., bottom) group of battery cells 36 in the first battery module 24A, and / or the temperature of the battery module 24.

[0161] To facilitate determining the operating parameters, the battery cell control unit 46 may receive sensor data indicative of the operating parameters from one or more sensors 108. Thus, in some embodiments, the sensors 108 may include one or more voltage sensors and / or one or more temperature sensors. For example, in the depicted embodiment, the first battery cell control unit 46A may receive sensor data indicative of the voltage of the first group of battery cells 36 from the first sensor 108A, the first group of battery cells including the first battery cell 36A and the second battery cell 36B. Additionally, the first battery cell control unit 46A may receive sensor data indicative of the voltage of the first battery module 24A from the second sensor 108B and sensor data indicative of the second group of battery cells 36 from the second sensor 108B, the second group of battery cells including the third battery cell 36C and the fourth battery cell 36D.

[0162] Additionally, as described above, module-level functionality may include centralizing communications from the respective battery modules 24 to the string control unit 50. Furthermore, cell-level functionality may include coordinating the operation of the battery cells 36 and / or cell groups in the respective battery modules 24 based on determined operating parameters. To enable provision of cell-level functionality, as described above, the hybrid battery control system architecture may dictate the infrastructure used in each cell control unit 46.

[0163] To help illustrate, Figure 12FIGURE 4 illustrates one embodiment of a battery cell control unit 46 that may be specified by a hybrid battery control system architecture. As depicted, the battery cell control unit 46 includes a first sensor communication interface 140, a second sensor communication interface 142, a first analog-to-digital converter 144, a second analog-to-digital converter 146, logic circuitry 148, and a serial communication interface 150. It should be understood that the components described are intended to be illustrative only. In other words, in actual implementations, the battery cell control unit 46 may include additional and / or fewer components.

[0164] With respect to the depicted embodiment, the processing infrastructure in the battery cell control unit 46 includes a first analog-to-digital converter 144, a second analog-to-digital converter 146, and logic circuitry 148 to provide battery cell-level functions and / or module-level functions. Specifically, the first analog-to-digital converter 144 and / or the second analog-to-digital converter 146 may convert data from an analog representation to a digital representation, for example, to facilitate further processing by the logic circuitry 148 and / or the string control unit 50.

[0165] As described above, the battery cell control unit 46 may provide computationally less complex functionality to facilitate reducing implementation-related costs, reducing size, and / or reducing the impact of the power consumption of the battery cell control unit 46 on the operation of the corresponding battery module 24. Therefore, in some embodiments, the logic circuitry 148 may operate based on relatively fixed circuit connections formed in the logic circuitry 148, for example, to process and / or analyze operating parameters related to the operation of the corresponding battery module 24 and / or battery cells 36 in the battery module 24 (process block 151).

[0166] Thus, in some embodiments, logic circuitry 148 may include one or more application-specific integrated circuits (ASICs), operational amplifiers, and / or logic gates. For example, in some embodiments, logic circuitry 148 may perform arithmetic operations such as addition, division, multiplication, and / or division. Additionally, in some embodiments, logic circuitry 148 may perform logic operations such as AND, OR, XOR, NOT, and / or NAND operations.

[0167] To facilitate providing battery cell 36 coordination functionality, the communication infrastructure includes a first sensor communication interface 140 and / or a second sensor communication interface 142. In some embodiments, the first sensor communication interface 140 can be communicatively coupled to the first sensor 108A, thereby enabling the battery cell control unit 46 to receive an analog representation of sensor data and enabling the first analog-to-digital converter 144 to convert the analog representation of the sensor data into a digital representation for further processing. Additionally, the second sensor communication interface 142 can be communicatively coupled to the second sensor 108B, thereby enabling the battery cell control unit 46 to receive an analog representation of sensor data and enabling the second analog-to-digital converter 146 to convert the analog representation of the sensor data into a digital representation for further processing.

[0168] Furthermore, to facilitate the string control unit 50 in providing module-level coordination functions, the communication infrastructure of the cell control unit 46 includes a serial communication interface 150, thereby enabling the cell control unit 46 to communicate cell-level operating parameters and / or module-level operating parameters to the string control unit 50, for example, via a high-voltage serial communication network. In this manner, the hybrid battery control system architecture can provide a cell control unit 46 building block and associated infrastructure for providing various cell / module-level functions.

[0169] In some embodiments, the design system 58 can facilitate the use of a hybrid battery control system architecture to implement the battery control system 26. In some embodiments, the design system can analyze the battery system 12 and indicate building blocks from the hybrid battery control system architecture for use in implementing the corresponding battery control system 26. For example, returning to Figure 9 In the second battery system 12B shown in FIG, the design system 58 detects the battery modules 24 and instructs the cell control unit 46 to be electrically coupled to each battery module 24. Additionally, the design system 58 may detect the battery strings 52 and instruct the string control unit 50 to be communicatively coupled and / or electrically coupled to the cell control unit 46 corresponding to the battery modules 24 in each battery string 52. Furthermore, the design system 58 may instruct the system control unit 48 to be communicatively coupled to the string control units 50 corresponding to the battery strings 52 in the battery system 12B.

[0170] In some embodiments, the design system 58 can relatively automatically implement the battery control system 26 based at least in part on the indications of implementations of the building blocks in the battery control system 26. In other embodiments, the design system 58 can communicate the indications of the implementations of the battery control system 26 for the building blocks to a manufacturing system, e.g., via the communication network 60 and / or the output device 64. Furthermore, in some embodiments, the design system 58 can communicate the indications of the building blocks, e.g., via the communication network 60 and / or the output device 64, to enable a user (e.g., an operator or a manufacturer) to implement the battery control system 26.

[0171] Additionally, as described above, the hybrid battery control system architecture can enable the battery control system 26 to be expanded to provide additional control-level functionality. For example, to provide chain-level functionality, the chain control unit 153 can be communicatively coupled to a string control unit 50 for use with battery strings 52 in a corresponding battery chain 44. As described above, using other hybrid battery control system architectures can have different impacts on implementation flexibility and / or implementation-related costs.

[0172] Exemplary hybrid battery control system architecture with integrated string control unit

[0173] To help illustrate, Figure 14 FIG2 shows a second battery system 12B including a battery control system 26 implemented using another hybrid battery control system architecture. As depicted, the second battery system 12B includes battery chains 44 connected in parallel between a positive bus 47 and a negative bus 49, each battery chain including battery modules 24 connected in series and organized into battery strings 52. Additionally, the battery control system 26 is implemented using a cell control unit 46, an integrated string control unit 150, and a system control unit 48 provided by the hybrid battery control system architecture. In some embodiments, the cell control unit 46 and / or system control unit 48 provided by the presently described hybrid battery control system architecture can be substantially the same as those in the previously described hybrid battery control system architecture.

[0174] However, the presently described hybrid battery control system architecture may specify an integrated string control unit 150 that, compared to the string control unit 50 provided by the previously described hybrid battery control system architecture, at least partially alters the functionality and / or infrastructure provided. Specifically, because a battery string 52 generally includes at least one battery module 24, the integrated string control unit 150 may integrate cell / module-level functionality with string-level functionality. In this manner, redundant infrastructure used to implement the battery control system 26 may be reduced, thereby facilitating a reduction in implementation-related costs.

[0175] In some embodiments, the integrated string control unit 150 can provide string-level functionality for the battery string 52 as well as cell / battery-level functionality for one battery module 24 in the battery string 52. For example, in the depicted embodiment, the first integrated string control unit 150A can provide string-level functionality for the first battery string 52A as well as cell / battery-level functionality for one battery module 24 in the first battery string 52A. Additionally, the second integrated string control unit 150B can provide string-level functionality for the second battery string 52B as well as cell / battery-level functionality for one battery module 24 in the second battery string 52B. Furthermore, the third integrated string control unit 150L can provide string-level functionality for the third battery string 52C as well as cell / battery-level functionality for one battery module 24 in the second battery string 52B.

[0176] Thus, in some embodiments, the integrated string control unit 150 can be physically coupled to a corresponding battery module 24 in a battery string 52. For example, the first integrated string control unit 150A can be physically coupled to a corresponding battery module 24 in the first battery string 52A. Indeed, in some embodiments, the integrated string control unit can be disposed on and / or within the housing of its corresponding battery module 24. In this manner, by providing the integrated string control unit 150, the hybrid battery control system architecture can facilitate reduced implementation-related costs, particularly in less complex battery systems 12 (e.g., having fewer battery modules 24 and / or fewer control stages).

[0177] To help illustrate, Figure 14 FIGURE 1 illustrates one embodiment of an integrated string control unit 150 that may be specified by a hybrid battery control system architecture. As depicted, the integrated string control unit 150 includes an integrated battery cell control unit 152, processing circuitry 154, a processing unit 156, a memory 158, an isolation barrier 56, a parallel communication interface 160, a serial communication interface 162, and a string relay communication interface 164. It should be understood that the components described are intended to be illustrative only. In other words, in actual implementations, the integrated string control unit 150 may include additional and / or fewer components.

[0178] With respect to the depicted embodiment, the functionality provided by the integrated battery cell control unit 152 can be generally similar to the functionality provided by the battery cell control unit 46. Thus, the processing infrastructure of the integrated battery cell control unit 150 includes processing circuitry 154, processing unit 156, and processing infrastructure of the integrated battery cell control unit, such as the first analog-to-digital converter 144, the second analog-to-digital converter 146, and / or logic circuitry 148. In some embodiments, the processing circuitry 154 and processing unit 156 can operate to provide string-level functionality similar to that of the string control unit 50. Additionally, in some embodiments, the string-level functionality provided by the processing circuitry 154 and processing unit 156 can at least partially overlap to facilitate increased operational reliability of the integrated string control unit 150.

[0179] For example, the processing circuit system 154 can operate based on programmable circuit connections formed in the processing circuit system and thus can include one or more field programmable logic arrays (FPGAs). In addition, the processing unit 156 can operate by executing instructions stored in the memory 158. Therefore, in some embodiments, the processing unit 156 can include one or more microprocessors, and the memory 158 can include a tangible, non-transitory computer-readable medium that stores instructions that can be executed by the processing unit 156. Therefore, in such embodiments, the memory 134 can include random access memory (RAM), read-only memory (ROM), rewritable non-volatile memory (e.g., flash memory), a hard drive, an optical disk, etc.

[0180] In addition, when the battery string 52 includes multiple battery modules 24, the integrated string control unit 150 can coordinate the operation of its corresponding battery module 24 with the operation of the other battery modules 24 in the battery string 52. To facilitate coordinated operation, the communication infrastructure includes a parallel communication interface 160 and / or a serial communication interface 162. In some embodiments, the parallel communication interface 160 can be communicatively coupled to a parallel communication network such as a controller area network (CAN), and the serial communication interface 162 can be communicatively coupled to a serial communication network such as a ripcord network. In this way, the parallel communication interface 160 and / or the serial communication interface 162 can enable the integrated string control unit 150 to receive cell-level and / or module-level operating parameters from the battery cell control units 46 of the other battery modules 24 in its corresponding battery string 52, and / or transmit instructions to the battery cell control units.

[0181] Additionally, in some embodiments, the serial communication interface 162 may enable the integrated string control unit 150 to receive string-level operating parameters and / or self-configuration information from, for example, other integrated string control units 150 corresponding to other battery strings 52 in the same battery chain 44. Additionally, in some embodiments, the parallel communication interface 160 and / or the serial communication interface 162 may enable the integrated string control unit 150 to transmit string-level operating parameters to the system control unit 48 and / or receive instructions (e.g., control commands) from the system control unit.

[0182] With respect to the depicted embodiment, the communication infrastructure of the integrated string control unit 150 also includes a string relay communication interface 164. In some embodiments, the string relay communication interface 164 can be communicatively coupled to a string relay that can be controlled to selectively electrically connect the battery string 52 to the battery system 12 and / or an electrical load. For example, the string relay communication interface 164 can enable the integrated string control unit 150 to transmit a control command instructing the string relay to open to electrically disconnect the battery string 52 from the battery system 12. Additionally, the string communication interface 164 can enable the integrated string control unit 150 to transmit a control command instructing the string relay to close to electrically connect the battery string 52 to the battery system 12.

[0183] As described above, in some embodiments, multiple battery strings 52 can be connected in series, for example as a battery chain 44, wherein each battery string 52 uses a corresponding integrated string control unit 150. In such embodiments, operating a string relay can selectively connect or disconnect multiple battery strings 52. Therefore, in such embodiments, the string relay can be communicatively coupled to the string communication interface 164 of one (e.g., master) integrated string control unit 150, thereby enabling the one integrated string control unit 150 to transmit control commands to the string relay. In this manner, the string communication interface 164 of other (e.g., slave) integrated string control units 150 can be communicatively coupled to other electrical components, such as a fan.

[0184] In some cases, including the integrated cell control unit 152 in the integrated string control unit 150 can facilitate reducing redundant infrastructure. For example, the communication infrastructure used to provide cell / module level functionality can be shared with the communication infrastructure used to provide string level functionality. Additionally, in some embodiments, the processing infrastructure used to provide cell / module level functionality can be shared with the processing infrastructure used to provide string level functionality. For example, the processing circuitry 154 and / or the processing unit 156 can provide processing for implementing cell / module level functionality in addition to string level functionality, which can avoid the use of separate logic circuitry in the integrated string cell control unit 152. In this way, by providing the integrated string control unit 150, the hybrid battery control system architecture facilitates reducing the costs associated with the implementation of the battery control system 26.

[0185] Furthermore, by specifying an integrated string control unit 150, the hybrid battery control system architecture can enable implementation of the battery control system 26 with fewer components (e.g., building blocks). For example, the hybrid battery control system architecture can enable implementation of the battery control system 26 for a battery system 12 including one battery module 24 using a single integrated string control unit 150, thereby avoiding the use of a cell control unit 46 and / or a system control unit 48. In this manner, the hybrid battery control system architecture can also facilitate increased implementation flexibility.

[0186] To facilitate determining string-level operating parameters, the integrated string control unit 150 may receive high-voltage power, e.g., from the battery module 24, and low-voltage power, e.g., directly from the low-voltage power source 54 and / or via the system control unit 48. Accordingly, the power infrastructure of the integrated string control unit 150 includes an isolation barrier 56 that electrically isolates electrical components operating in the high-voltage domain from electrical components operating in the low-voltage domain.

[0187] Although electrically isolated, the integrated string control unit 150 can still be communicatively coupled to the system control unit 48 and / or other electrical components, such as the supervisory control system 18. Therefore, to facilitate communication, the isolation barrier 56 can include an isolated communication interface 166. In some embodiments, the isolated communication interface 166 can include one or more digital communication buses, optocouplers, photocouplers, and / or optoisolators. In this manner, the processing circuitry 154 and / or the processing unit 156 can be communicatively coupled to the communication infrastructure of the integrated string control unit 150 via the isolated communication interface 166.

[0188] Furthermore, in some embodiments, the processing circuit system 154 and / or the processing unit 156 may operate in a high-voltage domain. However, to facilitate reducing the impact of the power consumption of the battery control system 26 on the operation of the battery system 12, the processing circuit system 154 and / or the processing unit 156 may receive power supplied by the low-voltage power supply 54. To facilitate the use of power supplied from the low-voltage power supply 54, the isolation barrier 56 may include a transformer 168. In operation, the transformer 168 may receive low-voltage power and generate high-voltage power, which may then be supplied to the processing circuit system 154 and / or the processing unit 156 while maintaining electrical isolation. When the power supply from the low-voltage power supply 54 is interrupted, the integrated string control unit 150 may switch to supplying power from the battery module 24 to the processing circuit system 154 and / or the processing unit 156.

[0189] Furthermore, to enable communication with components operating in different voltage domains, the serial communication interface 162 may include a low-voltage serial communication interface communicatively coupled to a low-voltage serial communication network and / or a high-voltage serial communication interface communicatively coupled to a high-voltage serial communication network. In this manner, in some embodiments, the low-voltage serial communication interface may communicatively couple the integrated string control unit 150 to the system control unit 48 and / or another integrated string control unit 150 via the low-voltage serial communication network. Additionally, in some embodiments, the high-voltage serial communication interface may communicatively couple the integrated string control unit 150 to one or more cell control units 48 via the high-voltage serial communication network. Similarly, in some embodiments, the parallel communication interface 160 may include a low-voltage parallel communication interface communicatively coupled to a low-voltage parallel communication network and / or a high-voltage parallel communication interface communicatively coupled to a high-voltage parallel communication network. In this manner, a hybrid battery control system architecture may provide an integrated string control unit 150 and associated infrastructure for providing various cell-level, module-level, and string-level functions.

[0190] Figure 15One embodiment of a process 170 for implementing the integrated string control unit 150 is described in

[17] . In general, the process 170 includes electrically coupling the battery cell control unit to a first power source (process block 172), communicatively coupling the battery cell control unit to a processing circuitry and / or a processing unit (process block 174), electrically coupling the processing circuitry and / or the processing unit to a transformer (process block 176), electrically coupling the transformer to a second power source (process block 178), and communicatively coupling the processing circuitry and / or the processing unit to a communication interface via an isolated communication interface (process block 180). In some embodiments, the process 170 may be implemented by a manufacturer and / or designer of the integrated string control unit 150, for example, using a processor such as the design processor 68 to execute instructions stored in a tangible, non-transitory, computer-readable medium such as the design memory 70.

[0191] Accordingly, in some embodiments, the design system 58 may instruct the integrated battery cell control unit 152 to be electrically coupled to a first power source (process block 172). As described above, the integrated battery cell control unit 152 may be electrically coupled to a corresponding battery module 24. In other words, in such embodiments, the first power source may be the battery module 24 and, therefore, a high-voltage power source. Additionally, in some embodiments, the integrated battery cell control unit 152 may be electrically coupled to the battery module 24, for example, via terminals of the battery module 24 and / or an internal bus within the battery module 24.

[0192] In addition, the design system 58 may instruct the integrated battery cell control unit 152 to be communicatively coupled to the processing circuitry 154 and / or the processing unit 156 (process block 174). In some embodiments, the integrated battery cell control unit 152 may be communicatively coupled to the processing circuitry 154 and / or the processing unit 156 via one or more internal communication buses. In this manner, a communication infrastructure (e.g., a communication interface) for communicatively coupling the integrated battery cell control unit 152 to a communication (e.g., CAN or Ripcord) network may be eliminated.

[0193] In addition, the design system 58 may instruct the processing circuitry 154 and / or the processing unit 156 to be electrically coupled to the transformer 168 (process block 176) and the transformer to be electrically coupled to the second power source (process block 178). As described above, in some embodiments, the transformer 168 may receive low-voltage power from the low-voltage power source 54. In other words, in such embodiments, the second power source is the low-voltage power source 54. Thus, in some embodiments, the transformer 168 may be electrically coupled to the low-voltage power source 54 via one or more electrical buses and / or via the system control unit 48.

[0194] Additionally, as described above, transformer 168 can generate high voltage power that is supplied to processing circuitry 154 and / or processing unit 156. Thus, in some embodiments, transformer 168 can be electrically coupled to processing circuitry 154 and / or processing unit 156 via one or more electrical buses. Furthermore, as described above, transformer 168 can be connected across isolation barrier 56 between a first (e.g., high) voltage domain and a second (e.g., low) voltage domain. Thus, in operation, transformer 168 can facilitate the use of power received in the second voltage domain to supply power for operating processing circuitry 154 and / or processing unit 156 in the first voltage domain.

[0195] Design system 58 may also instruct processing circuitry 154 and / or processing unit 156 to communicatively couple to parallel communication interface 160 and / or serial communication interface 162 via isolated communication interface 166 (process block 180). In some embodiments, processing circuitry 154 and / or processing unit 156 may be communicatively coupled to isolated communication interface 166 via one or more internal communication buses. Additionally, in some embodiments, isolated communication interface 166 may be communicatively coupled to parallel communication interface 160 and / or serial communication interface 162 via one or more internal communication buses.

[0196] As described above, in the integrated string control unit 150, the processing circuit system 154 and the processing unit 156 can be positioned on the opposite side of the isolation barrier 56 from the parallel communication interface 160 and the serial communication interface 162. Thus, the isolated communication interface 166 can be connected across the isolation barrier 56 to facilitate data communication between electrical components operating in different voltage domains. In this manner, in some embodiments, the isolated communication interface 166 can facilitate data communication between the processing unit 156 and the parallel communication network via the parallel communication interface 160. Additionally, in some embodiments, the isolated communication interface 166 can facilitate data communication between the processing circuit system 154 and the serial communication network via the serial communication interface 162.

[0197] As described above, the serial communication network can communicatively couple the plurality of integrated string control units 150 and / or the plurality of string control units 50, for example, in a daisy chain. In some embodiments, the serial communication network can facilitate the communication of string-level operating parameters between the plurality of integrated string control units 150 and / or the plurality of string control units 50, for example, to indicate when a fault is detected in a corresponding battery string 52. Additionally, in some embodiments, the serial communication network can facilitate self-configuration of one or more of the plurality of integrated string control units 150 and / or one or more string control units 50, for example, to determine an order within the serial communication network.

[0198] Automatic configuration and fault transmission of string control units

[0199] To help illustrate, Figure 16 1 shows an embodiment of a string control unit 50 connected in a serial communication network 182. It should be understood that the following techniques are described with respect to the string control unit 50 only to provide an illustrative example. In other words, the following techniques can also be applied to the integrated string control unit 150.

[0200] In the depicted embodiment, a serial communication network 182 (e.g., a ripcord network) communicatively couples a plurality of string control units 50, namely a first string control unit 50A, a second string control unit 50B, and a third (e.g., final) string control unit 50L. In some embodiments, the string control units 50 communicatively coupled via the serial communication network 182 may correspond to battery strings 52 included in the same battery chain 44. Therefore, it should be understood that only three string control units 50 are depicted to provide an illustrative example. In other embodiments, the serial communication network 182 may include two string control units 50 or more than three string control units 50.

[0201] In any case, to form a serial communication network 182, the string control units 50 are communicatively coupled via a serial communication bus 184 (e.g., a ripcord bus). In some embodiments, the serial communication bus 184 can be a unidirectional communication bus. In such embodiments, to form the serial communication network, the string control units 50 can be connected via the serial communication bus 184 in a daisy-chain configuration. For example, in the depicted embodiment, the first string control unit 50A is communicatively coupled to the second string control unit 50B via the first serial communication bus 184A, and so on down the daisy chain to the last string control unit 50L. In addition, the last string control unit 50L is communicatively coupled to the first string control unit 50A via the feedback serial communication bus 184F.

[0202] In this manner, the string control unit 50 can pass the serial communication (e.g., ripcord) signal along (e.g., through) the serial communication network 182 (e.g., daisy chain) and back to the first string control unit 50A. Therefore, in some embodiments, the first string control unit 50A can be considered a master string control unit. Additionally, the second string control unit 50B through the last string control unit 50L can be considered slave string control units.

[0203] In some embodiments, communicating serial communication signals in this manner can enable the master string control unit to determine the number of slave string control units connected to the serial communication network 182 and to self-configure based at least in part on the number of slave string control units. Additionally, in some embodiments, communicating serial communication signals in this manner can enable the slave string control units to determine their order in the serial communication network 182 and to self-configure based at least in part on the determined order. Furthermore, in some embodiments, communicating serial communication signals in this manner can facilitate communication when a fault is anticipated to exist in other string control units 50, for example, enabling the master string control unit to command a string relay to open when a fault is anticipated.

[0204] To help illustrate, Figure 17 186 for operating a string control unit 50 connected in a serial communication network 182 (e.g., a daisy chain). In general, process 186 includes generating a serial communication signal in a master string control unit (process block 188), transmitting the serial communication signal to the next string control unit in the serial communication network (process block 190), determining whether a slave string control unit remains in the serial communication network (determination block 192), and feeding the serial communication signal back to the master string control unit when no subsequent string control unit remains (process block 194). In some embodiments, process 186 can be implemented by operating a processing circuit system such as processing circuit system 130 or processing circuit system 154 based on programmable circuit connections. In addition, in some embodiments, process 186 can be implemented by using a processor such as processing unit 132 or processing unit 156 to execute instructions stored in a tangible, non-transitory computer-readable medium such as memory 134 or memory 158.

[0205] Accordingly, in some embodiments, the first (e.g., master) string control unit 50A may generate a first serial communication signal (process block 188). In some embodiments, the serial communication signal may include a high state and a low state. Additionally, in some embodiments, the serial communication signal may include a voltage signal or a current signal.

[0206] Furthermore, in some embodiments, the serial communication signal may be frequency modulated to convey information. For example, when no fault is detected, the frequency of the serial communication signal generated by the first string control unit 50A may be a master frequency (e.g., 100 Hz) indicating that the first string control unit 50A is the master string control unit in the serial communication network 182. On the other hand, when a fault is detected, the frequency of the serial communication signal generated by the first string control unit 50A may be a fault frequency (e.g., 500 Hz) indicating that a fault has been detected.

[0207] The first string control unit 50A may then pass the first serial communication signal to the second (e.g., next slave) string control unit 50B (process block 190). In some embodiments, the first string control unit 50A may pass the first serial communication signal to the second string control unit 50B via the first serial communication bus 184A. After receiving the first serial communication signal, the second string control unit 50B may determine the frequency of the first serial communication signal and operate accordingly.

[0208] To help illustrate, Figure 18 One embodiment of a process 196 for operating a slave string control unit is described in [ 196 ]. In general, process 196 includes receiving a serial communication signal at a string control unit (process block 198), determining whether a fault has been detected in the current string (decision block 200), outputting a serial communication signal having a fault frequency when a fault has been detected in the current string (process block 202), and determining the frequency of the received serial communication signal when no fault has been detected in the current string (process block 204). In addition, process 196 includes determining whether the frequency of the received serial communication signal is equal to the fault frequency (decision block 206), determining whether a fault has been confirmed in a previous string when the frequency of the received serial communication signal is equal to the fault frequency (decision block 208), and determining the order of the string control unit in the serial communication network when the frequency of the received serial communication signal is not equal to the fault frequency or when the previous string has not confirmed a fault (process block 210). Furthermore, process 196 includes determining a sequence frequency (process block 212) and outputting a serial communication signal having the sequence frequency (process block 214). In some embodiments, process 196 may be implemented by operating processing circuitry such as processing circuitry 130 or processing circuitry 154 based on programmable circuit connections. Additionally, in some embodiments, process 196 may be implemented by executing instructions stored in a tangible, non-transitory computer-readable medium such as memory 134 or memory 158 using a processor such as processing unit 132 or processing unit 156.

[0209] Accordingly, in some embodiments, the second string control unit 50B may receive the first serial communication signal from the first string control unit 50A (process block 198). As described above, in some embodiments, the second string control unit 50B may receive the first serial communication signal via the first serial communication bus 184A.

[0210] Additionally, the second string control unit 50B may determine whether a fault has been detected in a second battery string 52B, the second string control unit 50B, and / or a cell control unit 46 communicatively coupled to the second string control unit 50B (decision block 200). In some embodiments, the second string control unit 50B may determine whether a fault is expected in the second battery string 52B based at least in part on string-level operating parameters. Additionally, in some embodiments, the second string control unit 50B may determine whether a fault is expected in a battery module 24 and / or a battery cell 36 in the second battery string 52B based at least in part on cell / module-level operating parameters. For example, as will be described in greater detail below, a cell control unit 46 corresponding to a battery module 24 in the second battery string 52B may indicate to the second string control unit 50B whether a fault is expected.

[0211] In any case, when the second string control unit 50B determines that a fault is expected, the second string control unit 50B may output a second serial communication signal having a fault frequency (process block 202). In some embodiments, the fault frequency may be known by the string control unit 50 as an indication that a fault has been detected. For example, in some embodiments, the fault frequency may be 500 Hz. Thus, by outputting a second serial communication signal having a fault frequency, the second string control unit 50B may indicate to other string control units 50 communicatively coupled to the serial communication network 182 that a fault has been detected.

[0212] On the other hand, when the second string control unit 50B has not determined whether a fault is expected, the second string control unit 50B can determine the frequency of the first serial communication signal (process block 204). In some embodiments, the second string control unit 50B can determine the frequency of the first serial communication signal by determining the duration between pulses. For example, when the first serial communication signal alternates between a high state and a low state every 10 ms, the string control unit 50B can determine the frequency to be 100 Hz. Alternatively, when the first serial communication signal alternates between a high state and a low state every 2 ms, the second string control unit 50B can determine the frequency to be 500 Hz.

[0213] In this manner, the second string control unit 50B can determine whether the frequency of the first serial communication signal is equal to the fault frequency (decision block 206). Additionally, upon detecting the fault frequency, the second string control unit 50B can confirm whether a fault has been detected in another battery string 52 (decision block 208). In other words, in some embodiments, once the fault frequency is received, the second string control unit 50B cannot immediately determine that a fault has been detected in the battery system 12.

[0214] In contrast, since the detected fault may cause at least a portion of the battery system 12 to cease operation (e.g., disconnect), the second string control unit 50B may wait for a shorter duration before confirming that the frequency of the first serial communication signal actually indicates that a fault has been detected. For example, the second string control unit 50B may utilize a counter that increments when consecutive pulses of the first serial communication signal are at the fault frequency. In this manner, after the counter reaches a count threshold (e.g., five), the second string control unit 50B may confirm that a fault has been detected in another battery string 52. Thus, after having confirmed the fault, the second string control unit 50B may output a second serial communication signal having the fault frequency to the other string control units 50 communicatively coupled to the serial communication network 182 (process block 202).

[0215] On the other hand, when the received frequency does not equal the fault frequency and / or the fault has not been confirmed, the second string control unit 50B can determine the order of the second string control unit 50B in the serial communication network 182 based at least in part on the frequency of the first serial communication signal (process block 210). In some embodiments, the master frequency, which indicates that the string control unit 50 is the master string control unit in the serial communication network, can be known by the string control unit 50 communicatively coupled to the serial communication network 182. Accordingly, when the frequency of the first serial communication signal is the master frequency, the second string control unit 50B can determine that the previous string control unit 50 is the master string control unit. In this way, the second string control unit 50B can determine that its order in the serial communication network 182 is second and / or that it is the first slave string control unit 50 in the serial communication network 182.

[0216] Additionally, the second string control unit 50B may determine a sequence frequency indicative of its sequence in the serial communication network 182 (process block 212). In some embodiments, the second string control unit 50B may determine the sequence frequency based at least in part on the frequency of the first serial communication signal. For example, the slave string control unit may determine its sequence frequency by dividing (e.g., by half) the received frequency. To help illustrate, when the frequency of the first serial communication signal is 100 Hz, the sequence frequency determined by the second string control unit 50B may be 50 Hz.

[0217] The second string control unit 50B may then output a second serial communication signal having the sequential frequency (process block 214), for example, via the serial communication bus 184. In this manner, the string control unit 50 receiving the second serial communication signal may determine the sequence of the second string control unit 50B and configure itself accordingly.

[0218] Specifically, return to Figure 17In process 186, when subsequent string control units remain, the second string control unit 50B can output a second serial communication signal to the next slave string control unit in the serial communication network 182 (arrow 216). Thus, using the above process 196, each slave string control unit in the serial communication network 182 can operate to self-configure and / or indicate a detected fault. For example, when the third (e.g., last) string control unit 50L receives the second serial communication signal, the third string control unit 50L can determine the frequency of the second serial communication signal. When the frequency is a fault frequency (e.g., 500 Hz), the third string control unit 50L can, for example, confirm whether a fault has been detected by outputting a third serial communication signal having the fault frequency and self-adjust its operation accordingly. Additionally, when the frequency of the second serial communication signal is a sequential frequency (e.g., 50 Hz), the third string control unit 50L can determine that the second string control unit 50B is the first slave string control unit and, therefore, its sequence in the serial communication network 182 is third, and / or that it is the second slave string control unit in the serial communication network 182.

[0219] On the other hand, when there are no subsequent string control units remaining, the second string control unit 50B can feed back the second serial communication signal to the first (e.g., master) string control unit 50A (process block 194). Based at least in part on the feedback serial communication signal, the first string control unit 50A can determine whether a fault has been detected in any other battery string 52 in a manner similar to the slave string control unit. For example, the first string control unit 50A can determine the frequency of the second serial communication signal. In addition, when the frequency is a fault frequency (e.g., 500 Hz), the first string control unit 50A can confirm whether a fault has been detected and self-adjust operations accordingly, for example, by outputting a first serial communication signal having the fault frequency and / or commanding the string relay to open.

[0220] Additionally, based at least in part on the feedback serial communication signal, the first string control unit 50A may determine a configuration of the serial communication network 182, which may include the number of string control units 50 connected to the serial communication network 182 and / or the number of slave control units connected to the serial communication network 182. In some embodiments, the first string control unit 50A may determine the configuration of the serial communication network 182 by comparing the frequency of the feedback serial communication signal to a master frequency.

[0221] As described above, in some embodiments, the slave string control units may determine the sequential frequency by dividing the received frequency by a factor (e.g., 2). Thus, when the slave string control units determine the sequential frequency by dividing the received frequency in half, the first string control unit 50A may determine the configuration of the serial communication network 182 based at least in part on the number of times the master frequency is halved to arrive at the frequency of the feedback serial communication signal. For example, where the master frequency is 100 Hz and the frequency of the feedback serial communication signal is 50 Hz, the first string control unit 50A may determine that a total of two string control units 50 are connected to the serial communication network 182 and / or one slave string control unit is connected to the serial communication network 182. In a similar manner, where the master frequency is 100 Hz and the frequency of the feedback serial communication signal is 25 Hz, the first string control unit 50A may determine that a total of three string control units 50 are connected to the serial communication network 182 and / or two slave string control units are connected to the serial communication network 182.

[0222] In this manner, the first (e.g., master) string control unit 50A can adjust operation based at least in part on the configuration of the serial communication network 182. For example, based at least in part on the number of slave string control units connected to the serial communication network 182, the first string control unit 50A can determine the number of string control units 50 to which the first string control unit 50A can transmit control commands. Additionally, the configuration of the serial communication network 182 can provide the first string control unit 50A with insight into the implementation of the battery system 12. For example, based at least in part on the total number of string control units connected to the serial communication network 182, the first string control unit 50A can determine the number of battery strings 52 connected in the battery chain 44.

[0223] To help illustrate the above techniques, Figure 19 , a plot 218 is shown that provides a visual representation of the serial communication signals output by the first string control unit 50A, the second string control unit 50B, and the third (e.g., last) string control unit 50L. Specifically, the plot 218 includes a first waveform 220 that provides a visual representation of the first serial communication signal output by the first string control unit 50A between t0 and t4. Additionally, the plot 218 includes a second waveform 222 that provides a visual representation of the second serial communication signal output by the second string control unit 50B between t0 and t4. Furthermore, the plot 224 includes a third waveform 222 that provides a visual representation of the third serial communication signal output by the third string control unit 50L between t0 and t4.

[0224] Regarding the depicted embodiment, there may be no fault between t0 and t1. Thus, as depicted, the first string control unit 50A outputs a first serial communication signal having a frequency of 100 Hz (e.g., the main frequency). Additionally, as depicted, the second string control unit 50B outputs a second serial communication signal having a frequency of 50 Hz (e.g., half the received frequency). Furthermore, as depicted, the third string control unit 50L outputs a third serial communication signal having a frequency of 25 Hz (e.g., half the received frequency).

[0225] However, at t1, the first string control unit 50A determines that a fault is expected with respect to the first battery string 52A. Therefore, as depicted, the first string control unit 50A begins outputting a first serial communication signal having a frequency of 500 Hz (e.g., the fault frequency) at t1. Additionally, as depicted, the second string control unit 50B begins outputting a second serial communication signal having a frequency of 500 Hz at t2, after five (e.g., a count threshold) pulses of the first serial communication signal at 500 Hz. Furthermore, as depicted, the third string control unit 50L begins outputting a third serial communication signal having a frequency of 500 Hz at t3, after five pulses of the second serial communication signal at 500 Hz.

[0226] In this manner, the string control unit 50, communicatively coupled via the serial communication network 182, can self-configure and / or communicate detected faults. As described above, in some embodiments, the string control unit 50 can detect faults based at least in part on fault indications from the cell control unit 46. However, in some embodiments, the processing capabilities of the cell control unit 46 may be limited. Nevertheless, the cell control unit 46 can still utilize the processing infrastructure specified in the hybrid battery control system architecture described above to provide fault detection functionality.

[0227] Battery unit control unit fault detection

[0228] To help illustrate, Figure 20 , an embodiment of a battery module 24 and a battery cell control unit 46 is shown in FIG. As described above, the battery module 24 can include a plurality of battery cells 36. With respect to the depicted embodiment, the battery cells 36 in the battery module 24 are divided between a first battery cell group 226 and a second battery cell group 228. In some embodiments, the battery cells 36 can be equally divided between the first battery cell group 226 and the second battery cell group 228. For example, when the battery module 24 includes sixteen battery cells 36, the battery cells 36 can be divided such that the first battery cell group 226 and the second battery cell group 228 each include eight battery cells 36.

[0229] Furthermore, based on the hybrid battery control system architecture described above, the battery cell control unit 46 includes a first sensor communication interface 140, a second sensor communication interface 142, a first analog-to-digital converter 144, a second analog-to-digital converter 146, and a logic circuit system 148. As described above, the first sensor communication interface 140 can be communicatively coupled to the first sensor 108A that determines the operating parameters of the first battery cell group 226. Additionally, the second sensor communication interface 142 can be communicatively coupled to the second sensor 108B that determines the operating parameters of the second battery cell group 228 and a third sensor that determines the operating parameters of the entire battery module 24.

[0230] For example, in some embodiments, the first sensor communication interface 140 may receive an analog representation of the voltage of the first battery cell group 226 from the first sensor 108A. To facilitate subsequent processing, the first analog-to-digital converter 144 may generate a digital representation of the voltage of the first battery cell group 226. Additionally, the second sensor communication interface 142 may receive an analog representation of the voltage of the second battery cell group 228 from the second sensor 108B and an analog representation of the voltage of the battery module 24 from the third sensor 108C. To facilitate subsequent processing, the second analog-to-digital converter may generate a digital representation of the voltage of the second battery cell group 228 and a digital representation of the voltage of the battery module 24.

[0231] To facilitate detecting faults using battery cell control unit 46, logic circuitry 148 may process and / or analyze the digital representations of the measured voltages generated by first analog-to-digital converter 144 and second analog-to-digital converter 146. Specifically, logic circuitry 148 may include comparison circuitry 230, such as an operational amplifier, to facilitate comparing the voltages. Additionally, logic circuitry 147 may include arithmetic circuitry 232, such as a logic adder, to facilitate adding the voltages.

[0232] Figure 21One embodiment of a process 234 for detecting a fault using the battery cell control unit 46 is described in

[15] . Generally speaking, the process 234 includes determining an indication of a first battery cell group voltage using a first analog-to-digital converter (process block 236), determining an indication of a second battery cell group voltage using a second analog-to-digital converter (process block 238), determining a first indication of a battery module voltage using the second analog-to-digital converter (process block 240), determining a second indication of a battery module voltage based at least in part on the indication of the first battery cell group voltage and the indication of the second battery cell group voltage (process block 244), determining whether a difference between the first indication of the battery module voltage and the second indication of the battery module voltage is greater than a difference threshold (decision block 246), determining that a fault is expected when the difference is greater than the difference threshold (process block 246), and determining that a fault is not expected when the difference is not greater than the threshold (process block 248). In some embodiments, the process 234 can be implemented by operating the logic circuitry 148, for example, during its manufacturing process based on circuit connections formed in the logic circuitry 148.

[0233] Accordingly, in some embodiments, the logic circuitry 148 may determine a digital representation of the voltage of the first battery cell group 226 (process block 236). As described above, in some embodiments, the voltage of the first battery cell group 226 may be measured by the first sensor 108A and communicated to the first sensor communication interface 140. Additionally, as described above, the measured voltage of the first battery cell group 226 may be converted into a digital representation of the voltage and communicated to the logic circuitry 148.

[0234] Additionally, the logic circuitry 148 may determine a digital representation of the voltage of the second battery cell group 228 (process block 238). As described above, in some embodiments, the voltage of the second battery cell group 228 may be measured by the second sensor 108B and communicated to the second sensor communication interface 142. Additionally, as described above, the measured voltage of the second battery cell group 228 may be converted into a digital representation of the voltage and communicated to the logic circuitry 148.

[0235] Additionally, the logic circuitry 148 may determine a digital representation of the measured voltage across the battery module 24 (process block 240). As described above, in some embodiments, the voltage of the battery module 24 may be measured by the third sensor 108C and communicated to the second sensor communication interface 142. Additionally, as described above, the measured voltage of the battery module 24 is converted into a digital representation of the voltage and communicated to the logic circuitry 148.

[0236] Based at least in part on the digital representation of the first battery cell group voltage and the digital representation of the second battery cell group voltage, the logic circuitry 148 may determine a calculated voltage for the battery module 24 (process block 242). Specifically, the logic circuitry 148 may use the arithmetic circuitry 232 to determine the calculated voltage by adding the first battery cell group voltage and the second battery cell group voltage together.

[0237] Additionally, logic circuitry 148 may determine whether the difference between the measured voltage of battery module 24 and the calculated voltage of battery module 24 is greater than a difference threshold (process block 244). To determine the difference, logic circuitry 148 may use arithmetic circuitry 232 to subtract the measured voltage from the calculated voltage, or vice versa. Additionally, logic circuitry 148 may use comparison circuitry 230 to determine whether the difference is greater than the difference threshold.

[0238] In some embodiments, the difference threshold value can be predetermined and stored in the circuitry of the logic circuitry 148. In other embodiments, the difference threshold value can be provided to the logic circuitry from the string control unit 50, the integrated string control unit 150, the system control unit 48, the supervisory control system 18, and / or another electrical component, for example, based at least in part on user input. Furthermore, in some embodiments, the difference threshold value can be set to facilitate detection of faults in one or more specific components of the battery cell control unit 46, such as the first analog-to-digital converter 144 and / or the second analog-to-digital converter 146. Indeed, in some embodiments, different difference threshold values ​​can be used to determine faults in different components of the battery cell control unit 46 and / or to detect different types of faults in the battery modules 24. Furthermore, in some embodiments, the difference threshold value can vary based at least in part on the measured and / or calculated battery module voltage. For example, the difference threshold value can be a percentage of the measured battery module voltage.

[0239] Thus, when the difference is greater than the difference threshold, the logic circuitry 148 may determine that a fault is expected in the cell control unit 46 (process block 246). When a fault is expected, the cell control unit 46 may also indicate this to the string control unit 50, the integrated string control unit 150, the system control unit 48, and / or the supervisory control system 18. In this manner, the hybrid battery control system architecture may specify a cell control unit 46 that provides fault detection functionality even with limited processing power, thereby improving operational reliability while reducing implementation-related costs.

[0240] Accordingly, the technical effects of the technology provided by the present disclosure include providing implementation flexibility and / or reducing implementation-related costs for implementing a battery control system. In some embodiments, a hybrid battery control system architecture can be determined to provide building blocks (e.g., battery cell control units, string control units, and system control units) that can be used to implement various battery control systems. In order to determine the hybrid battery control system architecture, some functions provided by the battery control system can be concentrated into fewer building blocks, thereby reducing redundant infrastructure and therefore reducing implementation-related costs of the battery control system. On the other hand, some functions can be distributed to more building blocks, thereby providing a variety of possible control levels that can be used for the battery control system and thereby increasing implementation flexibility. In addition, the technical effects of the present disclosure can include improving the operational reliability of the battery control system by implementing fault detection in the battery cell control unit even when the battery cell control unit has limited processing power.

[0241] The specific embodiments described above have been shown by way of example, and it should be understood that these embodiments are susceptible to various modifications and alternative forms. It should be further understood that the claims are not intended to be limited to the specific forms disclosed, but are intended to cover all modifications, equivalents, and alternatives that fall within the spirit and scope of the present disclosure.

Claims

1. A battery system comprising: a low voltage power supply, wherein the low voltage power supply provides low voltage power; a battery control system electrically coupled to the low voltage power source and configured to control the operation of the battery system, wherein the battery control system comprises: a system control unit communicatively coupled to the low voltage power supply; a first integrated string control unit, the first integrated string control unit being communicatively coupled to at least one of the low voltage power supply and the system control unit, wherein the first integrated string control unit is configured to: determining a second module level operating parameter; and determining a first cascade level operating parameter based at least in part on the first module level operating parameter and the second module level operating parameter; controlling operation of the battery system based at least in part on the first cascade operating parameter; and The first integrated string control unit comprises: a communications interface configured to operate using the low voltage power received from the low voltage power source; processing circuitry and processing units; and an isolation barrier formed to electrically isolate the processing circuit system and the processing unit from the communication interface, wherein the isolation barrier comprises: an isolated communication interface configured to communicatively couple the processing circuitry and the processing unit to the communication interface across the isolation barrier; and A transformer is configured to receive the low voltage power from the low voltage power source.

2. The battery system according to claim 1, wherein: The first integrated string control unit is configured to determine the first string level operating parameter based at least in part on a third module level operating parameter.

3. The battery system of claim 2, further comprising a second integrated string control unit communicatively coupled to at least one of the low voltage power supply and the system control unit, wherein The second integrated string control unit is configured to: determining a fourth module level operating parameter; determining a second cascade level operating parameter based at least in part on the third module level operating parameter and the fourth module level operating parameter; and Operation of the battery system is controlled based at least in part on the second cascade operating parameter. 4 . The battery system of claim 3 , the second integrated string control unit being communicatively coupled to the first integrated string control unit via a serial communication network.

5. The battery system according to claim 3, wherein: The second integrated string control unit is configured to determine whether a fault is detected in the battery system; and The first integrated string control unit is configured to provide a disconnect instruction.

6. The battery system according to claim 1, wherein: At least one of the processing circuitry and the processing unit is designed to receive the low voltage power from the low voltage power supply.

7. The battery system according to claim 1, wherein: The processing circuitry and the processing unit are configured to receive high voltage power when supply of the low voltage power to the first integrated string control unit is interrupted.

8. The battery system according to claim 1, wherein: The battery system is operable in multiple voltage domains.

9. The battery system according to claim 1, wherein: The battery system includes a serial communication interface having a low voltage serial communication interface communicatively coupled to a low voltage serial communication network.

10. The battery system according to claim 1, wherein: The battery system includes a parallel communication interface having a low voltage parallel communication interface communicatively coupled to a low voltage parallel communication network.

11. The battery system according to claim 1, wherein: The isolation barrier includes the transformer for receiving the low voltage power.

12. The battery system according to claim 1, wherein: The battery control system is configured to receive the low voltage power from the low voltage power source.

13. A method for implementing a battery control system for controlling operation of a battery system, comprising: determining a first operating parameter; applying low voltage power to a first integrated string control unit; as well as The first integrated string control unit is implemented by the following operations: electrically coupling the first integrated string control unit to the battery system to enable the first integrated string control unit to determine a second operating parameter related to operation of the battery system; as well as The first integrated string control unit is communicatively coupled to a first battery cell control unit so that the first integrated string control unit can determine a third operating parameter related to the operation of the battery system based at least in part on the first operating parameter and determine a control command to command the battery system to adjust the operation of the battery system.

14. The method of claim 13, wherein: Implementing the first integrated string control unit includes: communicatively coupling a second analog-to-digital converter to a second sensor communication interface to enable the first integrated string control unit to receive a second analog representation of second sensor data from a second sensor and to generate a second digital representation of the second sensor data; and Processing circuitry, a processing unit, or both are communicatively coupled to the second analog-to-digital converter to enable the first integrated string control unit to determine the third operating parameter, determine the control command, or both based at least in part on the second digital representation.

15. The method of claim 14, wherein implementing the first integrated string control unit comprises: forming an isolation barrier to electrically isolate the processing circuitry, the processing unit, and the first communication interface from the second communication interface, wherein the isolation barrier includes the isolated communication interface; and The second communication interface is communicatively coupled to a second end of the isolated communication interface to enable the first integrated string control unit to communicate data within the battery control system via a low voltage serial communication network, a low voltage parallel communication network, or both.

16. The method of claim 13, wherein: Implementing the first integrated string control unit includes: forming an isolation barrier including a transformer; and A low voltage power source is electrically coupled to the first end of the transformer to enable the transformer to receive low voltage power from the low voltage power source.

17. The method of claim 15, comprising: implementing the system control unit by communicatively coupling the system control unit to the first integrated string control unit and the second integrated string control unit via a parallel communication network; Wherein, implementing the second integrated string control unit includes communicatively coupling the second integrated string control unit to the first integrated string control unit via the low voltage serial communication network.

18. The method of claim 13, wherein: Implementing the first integrated string control unit includes electrically coupling the first integrated string control unit to features of the battery system to enable the first integrated string control unit to determine a current flowing through the battery system.

19. A battery system comprising: Low voltage power supply; A battery control system, the battery control system being configured to control the operation of the battery system, wherein the battery control system comprises: a first battery cell control unit electrically coupled to the battery system, wherein the first battery cell control unit is configured to determine a first module-level operating parameter related to operation of the battery system; a first integrated string control unit, the first integrated string control unit being communicatively coupled to the first battery cell control unit and receiving low voltage power from the low voltage power source, wherein the first integrated string control unit is configured to: determining a second module-level operating parameter related to operation of the battery system; determining a first string level operating parameter related to operation of the battery system based at least in part on the first module level operating parameter and the second module level operating parameter; and controlling operation of the battery system based at least in part on the first cascade operating parameter; and The first integrated string control unit comprises: a parallel communication interface configured to communicatively couple the first integrated string control unit to a second integrated string control unit and a system control unit via a parallel communication network; a low voltage serial communication interface configured to communicatively couple the first integrated string control unit to the second integrated string control unit and the system control unit via a low voltage serial communication network; and An isolation barrier is configured to electrically isolate the parallel communication interface from the low voltage serial communication interface.

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