Battery system and battery management method

Abstract

A battery system (12) for a machine (10) includes one or more battery module cell bus bars (42) and one or more terminal bus bars (48). The one or more terminal bus bars (48) include a coupling (58) configured to couple the battery system (12) to one or more components of the machine (10). The battery system (12) also includes an interconnect system (46) that couples the one or more battery module cell bus bars (42) to the one or more terminal bus bars (48). The battery system (12) also includes a battery module circuit (64) coupled to one or more portions of the interconnect system (46). The battery module circuit (64) includes one or more thermistors (70) positioned to at least partially overlap with the one or more terminal bus bars (48).

Description

Technical Field

[0001] The present disclosure relates generally to systems, apparatus, and methods for battery systems in industrial equipment, and more particularly, to systems, apparatus, and methods for battery systems in industrial vehicles or machines. Background Art

[0002] An electric vehicle or semi-electric vehicle, such as a wheel loader, an excavator, a truck (e.g., a dump truck, a haul truck, an articulated dump truck, etc.), a crawler tractor (i.e., a bulldozer), a grader, a continuous miner, a feeder breaker, a bolter, a mining utility vehicle, a load-haul-dump (LHD) vehicle, an underground mining loader, an underground articulated truck, etc., includes one or more batteries. The one or more batteries include various connections (i.e., electrical connections) to power one or more motors, a heating and / or cooling system, (one or more) hydraulic systems, a navigation system, a lighting system, an electronic device, an auxiliary system, etc. However, one or more connections may fail, for example, due to damage, improper connection, long-term use, etc., and the connection failure may result in damage to one or more batteries and / or the machine, requiring repair, replacement, or otherwise shutting down the machine.

[0003] U.S. Patent No. 10,720,626 (the “'626 patent”), issued on July 21, 2020 to Harris et al., describes systems and methods for locating and managing battery cells in a battery pack of an electric vehicle. In particular, the '626 patent discloses a battery management system, and an interconnect assembly that communicates with the battery management system. In addition, the '626 patent discloses that the interconnect assembly includes one or more thermistors located proximate to the battery cells to sense the temperature of the battery cells. Furthermore, the thermistors may be connected via a flexible printed circuit board to form a temperature sensing strip. However, the thermistors of the '626 patent monitor the temperature of the battery cells, not the temperature of the battery terminals or bus bars. Furthermore, the system of the '626 patent does not monitor temperature to detect potential failure of one or more connections, and does not initiate one or more warnings or other preventive measures.

[0004] The systems, devices and methods of the present disclosure may address or solve one or more of the above problems and / or other problems in the art. However, the scope of the present disclosure is defined by the appended claims and is not limited by the ability to solve any particular problem. Summary of the invention

[0005] The present disclosure relates generally to the field of industrial vehicles. More specifically, the present disclosure relates to systems, methods, and apparatus for monitoring and controlling battery assemblies used with industrial vehicles, such as battery-powered electric or semi-electric machines.

[0006] In some aspects, a battery system for a machine may include one or more battery module unit buss bars, one or more terminal buss bars, an interconnect system, and a battery module circuit. The one or more terminal buss bars may include a connector configured to couple the battery system to one or more components of the machine. The interconnect system may couple the one or more battery module units to the one or more terminal buss bars. The battery module circuit may be coupled to one or more portions of the interconnect system. The battery module circuit may include one or more thermistors positioned to at least partially overlap the one or more terminal buss bars.

[0007] In some additional aspects, a battery management method may include initiating a machine operation of a machine. The machine may include a battery system, a battery management system coupled to the battery system, a motor powered by the battery system, and a user interface coupled to the battery management system. The battery system may include one or more battery module unit bus bars, one or more terminal bus bars, and a flexible circuit board including one or more thermistors. The one or more thermistors may at least partially overlap with the one or more terminal bus bars. The method may also include monitoring the temperature of the one or more terminal bus bars with the one or more thermistors, and initiating a first warning or action if the one or more thermistors detect a terminal bus bar temperature exceeding a first threshold temperature. The first warning or action may include signaling the user interface to indicate a high battery temperature warning.

[0008] In another aspect, a machine may include one or more ground engaging elements, a battery system, a battery management system coupled to the battery system, a motor powered by the battery system and configured to drive the one or more ground engaging elements, and a user interface coupled to the battery management system. The battery system may include one or more battery module cell buss, one or more terminal buss, and a flexible circuit board including one or more thermistors. The one or more thermistors may at least partially overlap the one or more terminal buss. If the one or more thermistors detect a terminal bus temperature that exceeds a threshold temperature, the battery management system may be configured to derate the motor or disconnect the battery system from the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is an illustration of an example machine including a control system according to aspects of the present disclosure.

[0010] Figure 2A A top view of an exemplary battery system having a battery management system according to aspects of the present disclosure is shown, and Figure 2Byes Figure 2A An enlarged view of a portion of.

[0011] Figure 3 A perspective view of a flexible or printed circuit board system for a battery system is shown according to an exemplary embodiment.

[0012] Figure 4 is a flow chart depicting an exemplary method for monitoring the temperature of one or more portions of a battery system and initiating one or more warnings or other preventative actions according to aspects of the present disclosure. DETAILED DESCRIPTION

[0013] Both the foregoing general description and the following detailed description are exemplary and illustrative only and do not limit the claimed features. As used herein, the terms "comprises," "comprising," "having," "including," or other variations thereof, are intended to encompass a non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. In addition, in the present disclosure, relative terms, such as, for example, "about," "substantially," "substantially," and "approximately," are used to indicate a possible variation of ±10% of the stated value.

[0014] Figure 1 A perspective view of an exemplary vehicle or machine 10, which may be an electric vehicle or machine, is shown. As discussed in detail below, the machine 10 includes a battery system 12 that includes one or more temperature sensors or thermistors ( Figure 2A , 2B and 3). Machine 10 may also include, for example, a battery management system 14 that communicates with one or more aspects or portions of battery system 12. Machine 10 also includes a controller 102 that is, for example, coupled to machine 10 or remote from the machine. Machine 10 may include one or more user interfaces 16 that are, for example, located in an operator station 18. Operator station 18 (e.g., a cab) may be located on machine 10, for example, in a center or front portion of machine frame 20, or may be remote from machine 10 (not shown). In these aspects, as shown in FIG. Figure 1 and 2AAs shown in , one or more portions of each of the battery system 12, the battery management system 14, the controller 102, and / or the user interface(s) 16 may communicate (e.g., via wired or wireless connections), for example, to form a control system 100. In these aspects, and as discussed in detail below, when the temperature of one or more terminals or bus bars of the battery system 12 is above one or more threshold temperatures, the battery management system 14, the controller 102, and / or the user interface 16 may initiate one or more warnings and / or one or more steps or preventative actions.

[0015] like Figure 1 As shown in , the battery system 12 can be positioned in the rear portion of the machine 10. Alternatively, the battery system 12 can be positioned anywhere on the machine 10. Additionally, in some aspects, the battery system 12 can be removable, for example, to be charged away from the machine 10, to be easily replaced with a charged battery system 12, thereby extending the operating time of the machine 10, reducing downtime for charging, etc.

[0016] The battery system 12 can power the motor 22 and / or other components of the machine 10. The machine 10 may include one or more ground engaging elements, such as wheels 24, which may be driven by the motor 22. In another aspect, the machine 10 may alternatively have tracks (not shown). In one aspect, the machine 10 may be fully electric, e.g., the machine 10 is powered entirely by the battery system 12. Although not shown, the machine 10 may be semi-electric (i.e., hybrid) and may include an engine, e.g., to help drive the wheels 24 and / or to power one or more additional components of the machine 10. In addition, although not shown, the machine 10 may include one or more unit controllers (i.e., motor controllers, engine controllers, etc.), which may be incorporated into the controller 102 or may be separate but communicatively connected to the controller 102.

[0017] Controller 102 may communicate with one or more features or portions of machine 10. Controller 102 may receive inputs and send outputs, for example, to operate machine 10, including initiating one or more indications or warnings on user interface 16, de-rating one or more components of machine 10, and / or stopping or shutting down one or more components of machine 10 or the entirety of machine 10. Although not shown, controller 102 may be coupled to or include one or more memory units that may contain instructions for controller 102 to initiate one or more displays or one or more preventive steps or procedures. Controller 102 may be a separate controller on machine 10, or may be integrated into a central vehicle controller (e.g., a main power or operating controller, etc.). Alternatively, controller 102 may be integrated into one or more of battery management system 12, motor control module, or another dedicated control module on machine 10. In one aspect, machine 10 may be an electric hydraulic wheel loader, and controller 102 may control one or more electrical switches or valves to control one or more hydraulic cylinders or electrical elements to operate machine 10.

[0018] The controller 102 may be embodied as a single microprocessor or multiple microprocessors, which may include systems for performing any of the operations mentioned herein. For example, the controller 102 may include a memory, an auxiliary storage device, a processor (such as a central processing unit), or any other system for completing tasks according to the present disclosure. The memory or auxiliary storage device associated with the controller 102 may be a non-transitory computer-readable medium that stores information that may help the controller 102 perform its functions (such as Figure 4 In addition, the memory or auxiliary storage device associated with the controller 102 may also store data received from various inputs or sensors associated with the machine 10. Many commercially available microprocessors can be configured to perform the functions of the controller 102. It should be understood that the controller 102 can be easily implemented as a general machine controller capable of controlling many other machine functions. Various other known circuits, including signal conditioning circuits, communication circuits, hydraulic or other actuation circuits, and other appropriate circuits, may be associated with the controller 102. As discussed herein, the controller 102 can receive various inputs (e.g., from various sensors), and based on the various inputs, the controller 102 can signal the initiation of one or more indications or warnings (e.g., on the user interface 16) and / or one or more preventive steps or procedures.

[0019] In addition, the machine 10 may include one or more implements 26 (e.g., buckets) that are coupled to the machine frame 20 and movable relative to the machine frame. As shown, the machine 10 may be a wheel loader having a bucket as the implement 26. The bucket may be coupled to the machine frame 20 and movable relative to the machine frame via one or more hydraulic systems 28, the hydraulic system including one or more groups of rods and cylinders that may be operated by movement and / or pressurization of hydraulic fluid via one or more pumps. In addition, the machine 10 may include one or more navigation systems 30 (e.g., global positioning systems, total station systems, laser radar systems, chord sensor systems, one or more proximity sensors, etc.), coupled thereto and / or communicating therewith. The machine 10 may also include one or more lighting systems 32, such as one or more lights. As discussed in more detail below, various aspects of the machine 10 may be powered by the battery system 12.

[0020] Although the machine 10 is shown as a wheel loader including a bucket as an implement 26, the present disclosure is not limited thereto. For example, the machine 10 can be an excavator with a bucket, a truck with a movable truck box, a tractor with a blade, a ripper, etc., a grader with a turntable and a leveling blade, or any other vehicle or machine with or without a movable or positionable implement. In addition, in some examples, the machine 10 can be a ship or marine application. In other aspects, the machine 10 can be an energy storage machine, such as a fixed energy storage device or other energy storage application. In these aspects, the battery system 12 and / or the motor 22 can help propel the machine or vehicle, and can also help, for example, control the movement and / or position of the corresponding (one or more) implements or other aspects of the machine 10 based on operator control. In other aspects, the battery system 12 can help power one or more other aspects of a machine, device or application.

[0021] Figure 2A and 2B Additional features of the battery system 12 are shown. As described above, the battery system 12 can be coupled to and power one or more aspects of the machine 10. The battery system 12 can include a battery module 40, for example, including a plurality of battery packs or modular units coupled to (i.e., welded to) a plurality of modular unit bus bars 42. Although not shown, a corresponding number of battery packs or modular units can be positioned adjacent to each modular unit bus bar 42 (i.e., in the Figure 2A). A plurality of module unit bus bars 42 may be coupled together and / or supported by a frame 44. As shown, in one aspect, the battery module 40 may include twelve module unit bus bars 42. However, it should be noted that the battery module 40 may include a fewer or greater number of module units and module unit bus bars 42, and that the module units and module unit bus bars 42 may be arranged in a parallel or mirrored arrangement (as shown) or in any other arrangement. In addition, the module units and module unit bus bars 42 may be substantially the same, or one or more of the module units and module unit bus bars 42 may have different sizes, powers, etc. In addition, the battery system 12 may include one or more cross bus bars 42A, for example as part of the battery module 40. The cross bus bar 42A may help control the operation of the battery module 40 including the module unit bus bar 42. For example, the cross bus bar 42A may help electrically connect two or more module unit bus bars 42. In some aspects, the cross bus bar 42A may help connect multiple module unit bus bars 42 in series.

[0022] The battery module 40 also includes an interconnect system 46 that includes or is coupled to one or more terminal bus bars 48. The interconnect system 46 can connect each module cell bus bar 42 to one or more terminal bus bars 48. The interconnect system 46 can also connect the crossbar 42A to other components of the battery module 40. For example, the interconnect system 46 can include two interconnect rails 50A, 50B, and can include a plurality of arms 52. The battery module 40 can include two terminal bus bars 48, wherein each of the interconnect rails 50A, 50B connects the module cell bus bar 42 to one of the two terminal bus bars 48. The arms 52 can extend from the interconnect rails 50A, 50B, for example, at approximately right angles, so as to connect the interconnect rails 50A, 50B to the respective module cell bus bars 42. Additionally, the interconnecting rails 50A, 50B may also be positioned adjacent to or proximate to one or more module unit bus bars 42, in which case one or more extensions 54 may extend from the interconnecting rails 50A, 50B, for example at substantially right angles, to connect the interconnecting rails 50A, 50B to the corresponding battery modules 40. Figure 2A , the extension 54 can be shorter than the arm 52. Alternatively, in some aspects, the extension 54 can be the same or similar length as the arm 52, for example, extending below or under the corresponding module unit bus bar 42. In these aspects, the arm 52 and / or the extension 54 can be coupled to the corresponding module unit bus bar 42 via a coupling element 56, which includes, for example, one or more welds, solders, bolts, or other suitable connection(s).

[0023] As shown, the battery module 40 may include two terminal bus bars 48, and the terminal bus bars 48 (together with the interconnection system 46) may be configured to route power from and / or to one or more module unit bus bars 42. For example, the terminal bus bars 48 may each include one or more couplings, ports, or openings 58 configured to receive a connection element and thus route power to or from one or more module unit bus bars 42. The interconnection system 46 may include one or more bus bar arms 60 to couple (i.e., electrically connect) the interconnection rails 50A, 50B to the terminal bus bars 48, for example, via one or more additional coupling elements 56. In addition, the interconnection system 46 may include one or more other coupling elements 56, for example, positioned on or near the arms 52 and / or extensions 54, to electrically couple each battery module 40 to the interconnection system 46, and thus to the terminal bus bars 48. In addition, the interconnection system 46 may include one or more terminals 62, for example, to electrically connect the battery module 40 to one or more components of the machine 10, for example, to the battery management system 14. Various components or portions of the interconnect system 46 , including the terminal busbar(s) 48 , interconnect rails 50A, 50B, arms 52 , extensions 54 , coupling elements 56 , busbar arms 60 , terminals 62 , etc., may be formed from a metallic material (eg, aluminum).

[0024] In addition, the battery module 40 includes a battery module circuit 64, for example, including a printed or flexible circuit board system 66 ( Figure 3 ).like Figure 2A As shown in , the battery module circuit 64 may include a plurality of voltmeters 68, for example, positioned on or near each module unit bus bar 42. The voltmeters 68 may help measure and / or detect the power flowing out of each module unit via each battery module unit bus bar 42 and / or the power remaining in each module unit. The voltmeters 68 may be positioned on the battery module circuit 64 such that each voltmeter 68 is positioned on a corresponding arm 52, or alternatively, on a portion of a corresponding interconnecting rail 50A, 50B adjacent to a corresponding extension 54.

[0025] In addition, if Figure 2B and 3 As shown in more detail in FIG. 1 , one or more thermistors 70 may be positioned on or near one or more portions of the battery module 40, for example, via a flexible circuit board system 66. For example, Figure 2A and 2B As shown in FIG. , thermistor(s) 70 may be coupled to the battery module circuit 64, for example, where the battery module circuit 64 is on or includes a flexible circuit board system 66. Figure 3). The thermistor 70 can be positioned on or near one or more terminal bus bars 48, for example, near the opening 58 of one or more terminal bus bars 48. In one aspect, one thermistor 70 is positioned on or near each terminal bus bar 48. Alternatively, one thermistor 70 can be positioned on or near only one terminal bus bar 48. In these examples, the thermistor 70 can be positioned on a portion of the flexible circuit board system 66 such that the thermistor 70 can be positioned on a portion of the bus bar arm 60 that overlaps a portion of the terminal bus bar 48. For example, the thermistor 70 can be positioned along approximately 50% of the length of the bus bar arm 60, approximately 60% of the length of the bus bar arm 60, approximately 70% of the length of the bus bar arm 60, approximately 80% of the length of the bus bar arm 60, approximately 90% of the length of the bus bar arm 60, etc. In addition, as described above, each thermistor 70 is part of the flexible circuit board system 66. For example, each thermistor 70 may include one or more connection wires 72 that may be incorporated into a corresponding portion of the flexible circuit board system 66 .

[0026] As mentioned above and as Figure 2AAs shown in , the battery management system 14 can be coupled to the battery system 12, for example, via one or more connections of the battery module circuit 64 (e.g., via one or more connections of the flexible circuit board 66). For example, the battery management system 14 can be coupled to one or more of the terminals 62. As discussed in more detail below, the battery management system 14 can initiate one or more warnings and / or one or more preventive steps or procedures based on one or more signals received from the battery module circuit 64. For example, the battery management system 14 can receive a signal from (one or more) thermistors 70 indicating (one or more) temperatures on or near one or more terminal bus bars 48. In this regard, an increased temperature on or near one or more terminal bus bars 48 can indicate one or more potential problems or faults (i.e., connection faults, improper connections, etc.) or other potentially dangerous conditions. For example, if the thermistor 70 signals a temperature above a certain temperature, the battery management system 14 can initiate one or more warnings and / or preventive measures. In these aspects, the battery management system 14 can signal different warnings and / or preventive measures to be taken based on the temperature measured by the thermistor 70. For example, if the thermistor 70 detects a first temperature, the battery management system 14 may signal the user interface 16 to indicate a high battery temperature warning. Then, if the thermistor 70 detects a second temperature that is higher than the first temperature, the battery management system 14 may signal the motor 22 or the engine (not shown) to derate. Further, if the thermistor 70 detects a third temperature that is higher than the second temperature, the battery management system 14 may signal the motor 22, the engine, other components of the machine 10, or the entirety of the machine 10 to shut down and cease operation. Alternatively or additionally, if the thermistor 70 detects one or more temperatures (i.e., one or more of the first temperature, the second temperature, the third temperature, or different temperatures), the battery management system 14 may disconnect one or more portions of the battery system 12 (i.e., the battery modules 40) from one or more other portions of the machine 10 (i.e., the motor 22), for example in addition to or in lieu of de-rating the motor 22.

[0027] Figure 3 The battery system 12 is shown separated from other aspects, such as the module unit bus bar 42, the frame 44 and the interconnect system 46 ( Figure 2A ) separate aspects of the flexible circuit board system 66. The flexible circuit board system 66 may include two flexible circuit boards 66A, 66B, which may be coupled to respective portions of the battery system 12. For example, the flexible circuit boards 66A, 66B may be substantially mirror images of each other. Each flexible circuit board 66A, 66B may include a longitudinal portion 74A, 74B, for example, to at least partially couple with the interconnect system 46 ( Figure 2A) of the interconnecting rails 50A, 50B. The longitudinal portions 74A, 74B may include one or more bent portions 76A, 76B, for example, which connect the longitudinal portions 74A, 74B to the terminal portions 78A, 78B. In addition, one or more reinforcement members 80A, 80B may be coupled to one or more portions of the flexible circuit boards 66A, 66B, for example, to help couple the flexible circuit boards 66A, 66B to the terminal portions 78A, 78B. As described above, the terminal portions 78A, 78B may at least partially overlap with the terminals 62, for example, to connect the flexible circuit boards 66A, 66B to the battery management system 14 ( Figure 2A ).

[0028] In addition, the flexible circuit boards 66A, 66B can each include a plurality of circuit arms, for example, a first circuit arm 82 and a plurality of second circuit arms 84, for example, to couple to the corresponding arms 52 and / or extensions 54 of the interconnecting rail. For example, the circuit arm 82 can include one or more thermistors 70. The circuit arm 82 can overlap the terminal bus bar 48 at least partially so that the thermistor 70 can monitor the temperature of the terminal bus bar 48, as described above. In addition, the circuit arm 84 can include one or more voltmeters 68, for example, which will be positioned on or near each module unit bus bar 42 and / or cross bus bar 42A, and measure and / or detect the power flowing out of each module unit bus bar 42 and / or cross bus bar 42A and / or the power remaining in each module unit bus bar and / or cross bus bar. In one aspect, the flexible circuit board 66A can include one first circuit arm 82 and six second circuit arms 84. In addition, in one aspect, the flexible circuit board 66B can include one first circuit arm 82 and seven second circuit arms 84. For both flexible circuit boards 66A, 66B, the second circuit arms 84 may extend from alternating sides of the longitudinal portions 74A, 74B.

[0029] It should be noted that the number and / or arrangement of the circuit arms 82, 84 on the respective flexible circuit boards 66A, 66B may vary, for example, depending on the number and / or arrangement of the module cell bus bars 42, the terminal bus bars 48, the interconnect rails 50A, 50B, the arms 52, the extensions 54, and / or other portions of the battery system 12. In these aspects, the first circuit arm 82 may be positioned to at least partially overlap the terminal bus bar 48, for example, to measure and / or detect the temperature of the terminal bus bar 48, and the second circuit arm 84 may be positioned adjacent to or proximate to the module cell bus bar 42 and / or the crossbar 42A, as described above.

[0030] Figure 41 is a flow chart depicting an exemplary method 400 that may be performed by the control system 100 (e.g., by one or more of the battery management system 14, the user interface 16, and / or the controller 104) to automatically monitor and / or control one or more aspects or portions of the machine 10. For example, when the machine 10 is in an operating mode, the control system 100 may monitor the temperature of one or more terminal bus bars 48. Additionally, if the temperature exceeds one or more threshold temperatures, the control system 100 may signal one or more warnings or initiate one or more preventive procedures or actions. The one or more warnings and / or preventive procedures or actions may include indicating an improper or potentially faulty connection to one or more terminal bus bars 48, de-rating one or more components of the machine 10, or shutting down or stopping one or more components of the machine 10.

[0031] Method 400 includes an initial step 402, which includes initiating machine operation. For example, step 402 may include powering on machine 10 or otherwise starting machine 10 and operating the machine. Operating machine 10 may include powering motor 22, manipulating implement 26, and / or activating one or more of hydraulic system 28, navigation system 30, lighting system 32, control system 100, or other aspects of machine 10. Step 402 may include operating actions, such as starting machine 10 and / or directing machine 10 to perform an operation (e.g., an earthmoving operation).

[0032] Next, the method 400 includes step 404, which includes monitoring the temperature of one or more terminal bus bars 48 with one or more thermistors 70. As described above, the thermistor(s) 70 are positioned on the flexible circuit board 66 and may be part of the battery module circuit 64. In addition, the thermistor(s) 70 are positioned on or near each terminal bus bar 48, for example, near the opening 58 on the terminal bus bar 48. As mentioned and as described in detail below, an increased temperature of the terminal bus bar(s) 48 may indicate one or more potential problems or faults (i.e., connection faults) or other potentially dangerous conditions.

[0033] The method 400 also includes one or more of steps 406, 408, or 410. For example, if the thermistor(s) 70 detects a first temperature (e.g., a first threshold temperature), step 406 includes initiating a first action or warning. For example, the first action or warning may include signaling the user interface 16 to indicate a high battery temperature warning, including, for example, a flashing light or icon, a beep or other sound, etc.

[0034] If thermistor(s) 70 detects a second temperature (e.g., a second threshold temperature that is greater than the first threshold temperature), step 408 includes initiating a second action or warning. In some aspects, the second action or warning may also include the first action or warning. The second action or warning may include signaling motor 22, an engine (not shown), or one or more other components of machine 10 to derate or otherwise reduce operating power or capacity.

[0035] If thermistor(s) 70 detects a third temperature (e.g., a third threshold temperature that is greater than the second threshold temperature), step 410 includes initiating a third action or warning. In some aspects, the third action or warning may also include one or more of the first action or warning or the second action or warning. The third action or warning may include signaling that motor 22, an engine (not shown), other components of machine 10, or the entirety of machine 10 shut down and cease operation.

[0036] Although not shown, method 400 may also include one or more other actions or warnings. For example, method 400 may include initiating display of a warning on an additional user interface, such as a user interface in a control station or otherwise remote from machine 10. Alternatively or additionally, method 400 may include modifying operating parameters of one or more other components or systems of machine 10, such as raising implement 26 to disengage from the ground, pausing or shutting down one or more of hydraulic system 28, navigation system 30, lighting system 32, or other systems or components of machine 10.

[0037] Industrial Applicability

[0038] The machine 10 and control system 100, including the battery system 12, the battery management system 14, the user interface 16, and the controller 102, can help monitor the connection(s) to one or more terminal bus bars 48. For example, one or more thermistors 70 can be positioned on or near the terminal bus bar 48. One or more thermistors 70 can be positioned near one or more openings 58, for example, where the terminal bus bar 48 is electrically coupled to one or more connection elements to route power to or from one or more module unit bus bars 42 and / or crossover bus bars 42A (e.g., via the interconnect system 46). Thus, the thermistors 70 can help monitor the temperature of the terminal bus bar 48. In addition, the control system 100, including the battery system 12, the battery management system 14, the user interface 16, and the controller 102, can help initiate one or more warning or preventive procedures or actions. One or more warning or preventive procedures or actions may help warn the operator(s) and / or help prevent damage to the battery system 12 and / or other components of the machine 10 that may be caused by a faulty or damaged battery connection.

[0039] As described above, the terminal 62 may be communicatively coupled to the battery management system 14. In this regard, the control system 100 including the battery system 12, the battery management system 14, the user interface 16, and the controller 102 may monitor the temperature of the terminal bus bar 48 and initiate one or more warnings or precautions in response to the detected temperature, for example, because an increase in the temperature of the terminal bus bar 48 may indicate an improper connection or a potential connection failure. One or more warnings or precautions may depend on the detected temperature. For example, if a thermistor 70 detects a terminal bus bar temperature exceeding a first threshold temperature, the control system 100 may signal the user interface 16 to indicate a high battery temperature warning, for example, including a flashing light or icon, a beep or other sound, etc. If a thermistor 70 detects a terminal bus bar temperature exceeding a second threshold temperature, the control system 100 may signal the motor 22, the engine (not shown), or one or more other components of the machine 10 to derate or otherwise reduce operating power or capacity. Additionally, if one of thermistors 70 detects a terminal bus temperature that exceeds a third threshold temperature, control system 100 may signal motor 22, an engine (not shown), other components of machine 10, or the entirety of machine 10 to shut down and cease operation. In these regards, control system 100 may help alert an operator of an improper connection and / or a potential connection failure, and / or may help prevent overheating and / or damage to terminal bus 48 and / or battery system 12 or other components of machine 10.

[0040] In addition, as described above, thermistor(s) 70 may be included on the flexible circuit board 66. In this regard, thermistor(s) 70 may be positioned on or near one or more terminal bus bars 48 when the flexible circuit board 66 is positioned on various portions of the interconnect system 46. Thermistor(s) 70 may be coupled to a connection line 72, which may also be included on the flexible circuit board 66. In this regard, the connection line 72 may be part of the battery module circuit 64 and thus connected to the terminals 62. In addition, the voltmeter 68 may help monitor the power remaining in one or more battery modules 40. Although not shown, the battery module 40 may include one or more additional temperature sensors, for example, located on or near one or more module cell bus bars 42, crossbars 42A, and / or on one or more portions of the flexible circuit board 66, for example, to help detect the temperature(s) of the module cell bus bars 42, crossbars 42A, portions of the flexible circuit board 66, and / or other portions of the battery module 40. For example, the battery system 12, the battery management system 14, the user interface 16, the controller 102, or other aspects of the control system 100 may monitor the temperature of multiple portions of the battery module 40, and may detect a temperature difference between one or more portions of the battery module 40. For example, one or more portions of the control system 100 may initiate one or more warnings or precautions in response to the detected temperature difference. Alternatively or additionally, if the thermistor 70 detects one or more temperatures (i.e., one or more of the first temperature, the second temperature, the third temperature, or different temperatures), the battery management system 14 may disconnect one or more portions of the battery system 12 (i.e., the battery module 40) from one or more other portions of the machine 10 (i.e., the motor 22), for example in addition to or in lieu of de-rating the motor 22.

[0041] In these aspects, the first temperature threshold may correspond to a first temperature difference threshold between the temperature at one terminal bus bar 48 and the temperature at another location of the battery module 40 (e.g., at one or more battery module cell bus bars 42), such as about 5° C. Similarly, the second temperature threshold may correspond to a second temperature difference threshold between the temperature at one terminal bus bar 48 and the temperature at another location of the battery module 40 (e.g., at one or more battery module cell bus bars 42), such as about 10° C. Finally, the third temperature threshold may correspond to a third temperature difference threshold between the temperature at one terminal bus bar 48 and the temperature at another location of the battery module 40 (e.g., at one or more battery module cell bus bars 42), such as about 15° C.

[0042] It will be apparent to those skilled in the art that various modifications and changes may be made to the disclosed systems, devices, and methods for battery systems without departing from the scope of the present disclosure. Other embodiments of systems, devices, and methods for battery systems will be apparent to those skilled in the art in view of the specification and the accompanying drawings. This specification, and in particular the examples provided herein, are intended to be considered as exemplary only, with the true scope of the present disclosure being indicated by the following claims and their equivalents.

Claims

1. A battery system (12) for a machine (10), wherein include: one or more battery module unit bus bars (42); one or more terminal bus bars (48) including couplings (58) configured to couple the battery system (12) to one or more components of the machine (10); an interconnect system (46) coupling the one or more battery module cell bus bars (42) to the one or more terminal bus bars (48); as well as A battery module circuit (64) is coupled to one or more portions of the interconnect system (46), wherein the battery module circuit (64) includes one or more thermistors (70) positioned to at least partially overlap the one or more terminal bus bars (48).

2. The battery system (12) of claim 1, further comprising a battery management system (14) coupled to the battery module circuit (64), and wherein if the one or more thermistors (70) measure a temperature exceeding one or more threshold temperatures, the battery management system (14) initiates one or more warnings or actions.

3. The battery system (12) of claim 2, further comprising a user interface (16), and wherein if the one or more thermistors (70) measure a temperature exceeding a first threshold temperature, the battery management system (14) signals the user interface (16) to indicate a high battery temperature warning.

4. The battery system (12) of claim 3, further comprising a motor (22), wherein if the one or more thermistors (70) measure a temperature exceeding a second threshold temperature that is higher than the first threshold temperature, the battery management system (14) signals the motor (22) to be derated.

5. The battery system (12) of claim 4, wherein the battery management system (14) signals the motor (22) to shut down if the one or more thermistors (70) measure a temperature exceeding a third threshold temperature that is higher than the second threshold temperature.

6. A battery system (12) according to any preceding claim, wherein the one or more terminal bus bars (48) include a first terminal bus bar and a second terminal bus bar (48), and wherein the one or more thermistors (70) include a first terminal thermistor and a second terminal thermistor (70), wherein the first thermistor (70) is positioned to at least partially overlap with the first terminal bus bar (48), and wherein the second thermistor (70) is positioned to at least partially overlap with the second terminal bus bar (48).

7. The battery system (12) of claim 6, wherein the first thermistor and the second thermistor (70) are positioned on a flexible printed circuit board (66A, 66B), and wherein the flexible printed circuit board (66A, 66B) further includes one or more voltmeters (68) to detect power delivered by the one or more battery module unit bus bars (42).

8. A battery system (12) according to claim 7, wherein the battery module circuit (64) connects the first thermistor and the second thermistor (70) and the one or more voltmeters (68) to a battery management system (14) via one or more terminals (62), and wherein the battery system (12) includes one or more reinforcement members (80A, 80B) adjacent to the one or more terminals (62) to connect the battery module circuit (64) to the one or more terminals (62).

9. A battery management method (400), wherein include: Initiating machine operation of a machine (10), wherein the machine (10) comprises: A battery system (12), wherein the battery system (12) includes one or more battery module unit bus bars (42), one or more terminal bus bars (48), and a flexible circuit board (66A, 66B), wherein the flexible circuit board includes one or more thermistors (70), wherein the one or more thermistors (70) at least partially overlap the one or more terminal bus bars (48); a battery management system (14) coupled to the battery system (12); a motor (22) powered by the battery system (12); and a user interface (16) coupled to the battery management system (14); monitoring the temperature of the one or more terminal bus bars (48) with the one or more thermistors (70); and If the one or more thermistors (70) detect a terminal bus bar temperature exceeding a first threshold temperature, a first warning or action is initiated, wherein the first warning or action includes signaling the user interface (16) to indicate a high battery temperature warning.

10. The method (400) according to claim 9, further comprising: include: If the one or more thermistors (70) detect a terminal bus bar temperature exceeding a second threshold temperature that is higher than the first threshold temperature, a second warning or action is initiated, wherein the second warning or action includes de-rating the motor (22).

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