Vehicle battery system including response to energy consumption event

Abstract

A method for responding to an energy consumption event includes providing electrical energy from an external source to a vehicle energy storage component until the energy storage component is charged to a threshold state-of-charge percentage. An external data source is monitored using a controller for the occurrence of an energy consumption event in at least one connected system. The controller responds to the occurrence of an energy consumption event by charging the remainder of the vehicle energy storage component.

Description

Technical Field

[0001] The present disclosure relates to energy storage and charging systems for electric vehicles, and more particularly to systems for identifying and responding to energy depletion events. Background Art

[0002] Electric and hybrid electric vehicles include energy storage systems, such as battery packs, that store electrical energy when the vehicle is not in operation and utilize the stored electrical energy when the vehicle is in operation. In a typical example, a controller charges the battery to full (100% state of charge), or as close to full as possible, in preparation for the next vehicle operation. Existing systems typically maximize charging to full as quickly as possible in order to minimize charging time.

[0003] Existing systems allow vehicle operators to begin operating the vehicle at maximum range potential in the shortest possible period of time. However, existing systems do not allow for the charging profile to be altered to accommodate external events that may benefit from a safe energy consumption path. Therefore, it is desirable to create an energy storage and charging system that allows the charging profile of an electric vehicle to be responsive to one or more energy consumption events occurring in a connected external system. Summary of the invention

[0004] In an exemplary embodiment, a method includes providing electrical energy from an external source to a vehicle energy storage component until the energy storage component is charged to a threshold state of charge percentage, monitoring the external data source with a controller for the occurrence of an energy depletion event in at least one connected system, and responding to the occurrence of the energy depletion event by charging a remaining portion of the vehicle energy storage component.

[0005] In addition to one or more features described herein, the method includes monitoring whether a vehicle energy consumption event still exists when the remainder of the vehicle energy storage component has been fully charged, and in response to the energy consumption event still existing, one of: consuming energy from the energy storage component while charging the vehicle energy storage component so that zero net current passes through the vehicle energy storage component, and disconnecting the vehicle energy storage component from the vehicle power system.

[0006] In addition to one or more features described herein, consuming energy from the vehicle energy storage component includes one of: converting energy from the vehicle energy storage component into waste heat, operating a vehicle system or component, and providing energy from the vehicle energy storage component to at least one external device.

[0007] In addition to one or more features described herein, converting energy from the vehicle energy storage component to waste heat includes one of: operating a vehicle heating ventilation and cooling (HVAC) system, spinning a misfire engine, and operating vehicle power electronics.

[0008] In addition to one or more features described herein, converting energy from the vehicle energy storage component into waste heat also includes absorbing waste heat in a vehicle battery such that the vehicle energy storage component operates as a radiator.

[0009] In addition to one or more features described herein, operating the vehicle HVAC system includes at least one of: simultaneously operating heating and cooling portions of the vehicle HVAC system, and simultaneously operating heating and cooling portions of a power electronics and vehicle energy storage component temperature control system.

[0010] In addition to one or more features described herein, the energy depletion event is a fault in a connected energy storage bank, and wherein the connected energy storage bank is a charging power source for a charging operation.

[0011] In addition to one or more features described herein, the energy consumption event is a negative energy rate from a power grid, and wherein the power grid is a charging power source for the charging operation.

[0012] In addition to one or more features described herein, consuming energy from the energy storage component includes increasing power draw from one or more vehicle component auxiliary loads, the one or more vehicle auxiliary loads including at least one of a cab fan, an under-hood fan, a drive pump, an actuator, a resistive heater, a light, and an onboard computer module.

[0013] In another exemplary embodiment, a vehicle includes: a propulsion system having at least one electric motor powered by a vehicle energy storage component; a plurality of auxiliary systems configured to receive operating power from the vehicle energy storage component and one of a vehicle power system capable of receiving power from the vehicle energy storage component; a charger configured to interface with an external power source and provide power to the vehicle energy storage component; and a controller configured to control the distribution of power through the vehicle, the controller including a memory storing instructions for causing the vehicle to direct electrical energy from the external power source to the vehicle energy storage component until the vehicle energy storage component is charged to a threshold state of charge percentage, using the controller to monitor an external data source for energy depletion events, and responding to the occurrence of the energy depletion event by charging a remaining portion of the vehicle energy storage component.

[0014] In addition to one or more features described herein, monitoring whether an energy depletion event continues when the remainder of the vehicle energy storage component has been fully charged, and in response to the energy depletion event continuing, one of: depleting energy from the energy storage component while charging the vehicle energy storage component such that zero net current passes through the vehicle energy storage component, and disconnecting the vehicle energy storage component from the vehicle electrical system.

[0015] In addition to one or more features described herein, consuming energy from the vehicle energy storage component includes one of converting energy from the vehicle energy storage component into waste heat and providing energy from the vehicle energy storage component to at least one external device.

[0016] In addition to one or more features described herein, converting energy from the vehicle energy storage component to waste heat includes one of: operating a vehicle heating ventilation and cooling (HVAC) system, and operating vehicle power electronics.

[0017] In addition to one or more features described herein, operating the vehicle HVAC system includes operating heating and cooling portions of the vehicle HVAC system simultaneously.

[0018] In addition to one or more features described herein, the energy consumption event is one of: a fault in a connected energy storage group, and wherein the connected energy storage group is a charging power source for the charging operation, and a negative energy rate from a power grid, and wherein the power grid is a charging power source for the charging operation.

[0019] In addition to one or more features described herein, consuming energy from the vehicle energy storage component includes increasing power draw from one or more vehicle component auxiliary loads, the vehicle auxiliary loads including at least one of a cab fan, an under-hood fan, a drive pump, an actuator, a resistive heater, a lamp, and an onboard computer module.

[0020] In another exemplary embodiment, a method includes providing electrical energy from an external source to a vehicle energy storage component, monitoring the external data source using a controller for the occurrence of an energy consumption event in at least one connected system external to the vehicle, and responding to the occurrence of the energy consumption event by consuming excess energy using at least one vehicle system.

[0021] In addition to one or more features described herein, consuming energy includes increasing power draw from one or more vehicle component auxiliary loads, the vehicle auxiliary loads including at least one of a cab fan, an under-hood fan, a drive pump, an actuator, a resistive heater, a lamp, and an onboard computer module.

[0022] In addition to one or more features described herein, the energy depletion event is a fault in a connected energy storage bank, and wherein the connected energy storage bank is a charging power source for a charging operation.

[0023] In addition to one or more features described herein, the energy consumption event is a negative energy rate from a power grid, and wherein the power grid is a charging power source for the charging operation.

[0024] The above features and advantages and other features and advantages of the present disclosure will become apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Other features, advantages and details appear, by way of example only, in the following detailed description, which refers to the accompanying drawings, in which:

[0026] Figure 1 is a vehicle including a battery-based energy storage system;

[0027] Figure 2 It is in charging operation Figure 1 vehicles; and

[0028] Figure 3 is used to give Figure 1 and 2 A method for charging a vehicle while allowing the charging profile to respond to energy depletion events. DETAILED DESCRIPTION

[0029] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0030] As used herein, the term module refers to a processing circuit, which may include an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that executes one or more software or firmware programs, combinational logic circuits, and / or other suitable components that provide the described functionality.

[0031] As used herein, an energy consumption event is an event in which it is desirable to consume electrical energy safely without moving the vehicle.

[0032] For example, energy depletion events may occur when a wall mounted charging station fails and / or is overcharged, electricity costs are negative, a power surge occurs, or any similar event occurs, where it may be necessary to divert power from an external source to or through the vehicle power system.

[0033] As used herein, a non-operating mode of a vehicle is a mode in which the vehicle is stationary, typically for a relatively long period of time. Typically, the non-operating mode occurs when the vehicle is parked and an operator is not present.

[0034] According to an exemplary embodiment, a battery system controller for an electric or hybrid electric vehicle is configured to charge an energy storage system (e.g., a battery) within the vehicle to a threshold charge level when the vehicle is not in operation. The threshold charge level is less than a full charge of the energy storage system. Once the threshold charge level is reached, the charging operation stops, and the remaining charge capacity of the energy storage system is reserved.

[0035] At the same time, the battery system controller monitors input data from one or more external sources connected to the vehicle for energy depletion events. An energy depletion event can be any situation in which it is desirable or beneficial for the vehicle to receive and consume external excess energy. The excess energy received is initially used to fill the storage capacity of the reserve. If the energy depletion event still exists once the reserve is full, the excess energy is converted into waste heat in the vehicle systems or transferred through the vehicle to one or more external systems that can utilize the excess energy. In some systems, after the energy depletion event has passed, the controller causes the vehicle to discharge the energy storage system back to a threshold level and continues to monitor for energy depletion events.

[0036] Continuing with the general system referenced above, Figure 1 An embodiment of a motor vehicle 10 is shown that includes a battery system controller 24 configured to control a battery system. The vehicle 10 includes a body 12 that at least partially defines an occupant compartment 14. The body 12 also supports various vehicle subsystems, including a propulsion system 16, a battery system 22, other subsystems that support the functionality of the propulsion system 16 and other vehicle components, such as a braking subsystem, a suspension system, a steering subsystem, a fuel injection subsystem, an exhaust subsystem, etc.

[0037] The vehicle 10 may be an internal combustion engine vehicle, an electric vehicle (EV), or a hybrid vehicle. In one embodiment, the vehicle 10 is a hybrid vehicle that includes an internal combustion engine system 18 and at least one electric motor assembly. For example, the propulsion system 16 includes a first electric motor 20 and a second electric motor 21. The motors 20 and 21 may be configured to drive wheels 23 on opposite sides of the vehicle 10. Any number of motors located in various additional locations around the vehicle 10 may be used to provide mechanical rotation for the corresponding systems and subsystems.

[0038] The battery system 22 can be electrically connected to the motors 20 and 21 and / or other components, such as vehicle electronics. The battery system 22 can be configured as a rechargeable energy storage system (RESS) and include a plurality of battery cells 28 divided into a plurality of sections. Alternatively, other types of vehicle energy storage components can be used to store electrical energy within the battery system 22. The battery system controller 24 is included in the battery system 22 and controls the charging and discharging functions of the batteries within the battery system 22. In an alternative configuration, the battery system controller 24 can be a universal vehicle controller away from the battery system 22 and configured to control multiple systems and / or subsystems. The universal vehicle controller can be located anywhere within the vehicle 10. In yet another alternative, the battery system controller 24 can be a distributed control system including a plurality of coordinated controllers throughout the vehicle 10, including controllers within the battery system 22 and controllers away from the battery system 22.

[0039] Continue to refer Figure 1 , Figure 2 The vehicle 100 is shown in a non-operating mode set for charging. Figure 1 The vehicle configuration is Figure 2 Although it will be appreciated that the system described and shown in Figure 2 and Figure 3 The system can be implemented in any vehicle including a controller and a charging system, and is not limited to Figure 1 The vehicle 100 includes a power distribution controller 110, which is configured to control the power distribution of the entire vehicle 100 and may be a battery system controller 24 ( Figure 1 ), a common vehicle controller, a distributed network of vehicle controllers communicating with each other, or any other vehicle controller configuration.

[0040] The controller 110 controls the distribution of power to the lights 120, the HVAC system 122, and any number of other auxiliary vehicle systems 124 (including fans, interior lights, mirror controls, window actuators, door locks, and any similar power systems within the vehicle), as well as other systems. In addition, the controller 110 controls the operation of the charger 150, which is configured to connect to an external power source and provide power to the vehicle. In some examples, the vehicle 100 can be configured to distribute power to one or more external electronic systems 140, and to provide power from the vehicle 100 to the external systems 140 when the vehicle 100 is not operating. The distribution of power to the external system can be through the charger 150, via wireless power distribution, through another connection manually established by the vehicle operator, a vehicle-to-load connection (where the vehicle can power a 120V / 240V outlet into which an external device can be plugged in and receive power), or any other power connection between the vehicle 100 and the external electronic system 140.

[0041] The flow of power within the vehicle is generally described herein as being from the wall to the vehicle through the charger 150. It should be understood that the actual power flow will be more complex and may include multiple steps, including power conversion and power transmission between multiple systems. For example, large electric motors, heaters, and compressors are powered directly from the high voltage bus (~300V+). In the case of running heated seats in the vehicle (12 / 48V powered), the heated seats take 12V power from the low voltage bus, and the auxiliary power module takes the high voltage power and converts it to low voltage power. Therefore, the power flow in this example is from an external source to the vehicle high voltage bus, to the auxiliary power module, to the vehicle low voltage bus, to the heated seats.

[0042] In addition to controlling power to and from the vehicle, the controller 110 can be connected to one or more external data sources, including a data connection to a wall storage unit 130, a data connection to an electrical grid 132, and / or a data connection to any other data source, including an internet-based database, a cellular or wifi connection, and / or a direct wired data connection (e.g., a USB port, a CAN or equivalent on-board diagnostic port, etc.). Additionally, in some examples, a vehicle operator can manually input data or other information into the controller 110 via a user interface, such as a touch screen, tablet, cell phone, or any other similar app-based device that communicates with the controller 24, 110.

[0043] The controller 110 includes one or more software modules configured to evaluate input data and identify the occurrence of an event external to the vehicle 100 that would benefit from the storage and / or consumption of electrical energy within the vehicle 100, thereby allowing the vehicle 100 to operate as a bypass or passthrough to release energy. For example, the external event may include a fault in a connected wall charger that requires discharge, excess power supplied to the wall charging system, a negative energy rate from the grid, a fault or thermal runaway event in a stationary battery connected to the wall charging unit, an excess supply of power from a solar / wind energy source mounted on a premises, or any similar event.

[0044] Continue to refer Figure 1 and Figure 2 of vehicles, Figure 3 A process 200 is shown implemented by the battery system controller 24 and / or the vehicle controller 110. The process 200 controls the charging operation of the vehicle 10, 100 while the vehicle 10, 100 is not operating and is configured for charging operations. The computer modules for implementing the process 200 are stored in the controller memory of the controller 24, 110.

[0045] In contrast, process 200 uses a smart charging process to reserve charging space within a vehicle battery or other energy storage system to allow vehicle 10 , 100 to help handle energy depletion events that may occur within one or more systems external to vehicle 10 , 100 that are connected to vehicle 10 , 100 using one or more data connections to external systems 130 , 132 , 134 .

[0046] Initially, at step 210, the vehicle operator places the vehicle 10, 100 in charging mode and begins a charging operation. Simultaneously, at a receive data step 220, the vehicle 10, 100 begins receiving data from one or more external systems 130, 132, 134 connected to the vehicle 10, 100. In an alternative example, the data may be manually entered by the operator through a user interface (e.g., a vehicle touch screen) or as part of a continuous feed that the vehicle 10, 100 always receives when the vehicle 10, 100 is placed in charging mode. When charging the vehicle, the battery is charged to a threshold state of charge (e.g., 80% charged), and once the threshold is reached at a reserve storage step 230, the controller 24, 110 stops charging. As data from external sources is monitored, the controller 24, 110 monitors for the occurrence of energy consumption events and identifies when such an event occurs at an identify condition step 240. Any known process may be used to identify the event.

[0047] When the event is identified, the controller 24, 110 begins charging the reserve portion of the battery until the portion is charged to the full charge state of the reserve from the source step 250. The energy source used in this case is the source of the energy consumption event. For example, if the energy consumption event is a faulty electrical wall storage that requires power diversion, the vehicle fills the reserve from the wall storage, thereby diverting energy from the wall storage. In another example, when the energy consumption event is a negative energy cost of electricity drawn from the grid, the vehicle uses the grid to fill the reserve.

[0048] Once the reserve portion has been filled, the controller 24, 110 checks in check 266 whether the energy consumption event has been resolved (no longer exists). When the energy consumption event has been resolved, the controller 24, 110 ends the charging operation in step 280. In an alternative example, the check 266 checks whether the energy consumption event has been resolved or the reserve portion has been filled. In this example, when either event occurs, the controller 24, 110 ends the charging operation in step 280.

[0049] Alternatively, once the reserve storage capacity has been filled, if an energy depleting event is ongoing, the controller 24, 110 causes the vehicle to deplete energy while simultaneously charging the vehicle battery from the source of the energy depleting event at step 270 such that zero net current flows through the battery.

[0050] In another example, when the battery is fully charged, the vehicle battery is disconnected from the vehicle power system and the power system operates as a pass-through to directly power other high voltage vehicle components (eg, heater, motor, compressor, etc.) using wall power.

[0051] Energy consumption may be in the form of operating the vehicle system in a non-productive manner. Non-productive energy consumption using vehicle systems may occur in a variety of ways. In one example, the vehicle 10, 100 operates as a pass-through and converter and provides energy to a second external component such as a battery pack, a power grid, a home power system, etc. In another example, when the vehicle does not have any occupants, energy can be consumed by running the vehicle HVAC system. The heating system, the cooling system, or both can be operated to consume energy. In another example, energy can be consumed by running the heating and cooling parts of the power electronics and the vehicle energy storage component temperature control system at the same time. In another example, energy is consumed by running one or more auxiliary vehicle systems, including but not limited to window actuators, door locks, cab fans, under-hood fans, power electronics, disengaged motors, drive pumps, resistive heaters, steering wheels, heated glass panels, heated mirrors, lights (e.g., headlights), onboard computers / modules, or any other systems. It should also be understood that the energy consumption modes described are not exhaustive, and each mode can be used alone or in combination with other listed modes and / or alternative modes of energy consumption.

[0052] In another example, consumption may take the form of the vehicle operating as a pass-through and directing excess energy from the energy consumption event source to one or more additional systems 140 external to the vehicle. In an example where a single vehicle is charged from the grid via a wall plug, the external systems 140 may include a home electrical system, a wall mounted electrical storage device, or any similar system.

[0053] The terms "one" and "an" do not indicate a limitation of quantity, but rather indicate the presence of at least one of the referenced items. The term "or" means "and / or", unless the context clearly indicates otherwise. References to "an aspect" throughout the specification mean that a particular element (e.g., feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in various aspects.

[0054] Unless stated to the contrary, schematic representations do not correspond one-to-one to physical structures, and the relative positioning, size, orientation, or other configuration of components within the schematic representations are not intended to be limiting.

[0055] When an element such as a layer, film, region, or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.

[0056] Unless otherwise indicated herein, all test standards are the most recent standards in effect as of the filing date of the present application or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.

[0057] Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0058] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from the scope thereof. In addition, many modifications may be made to adapt specific situations or materials to the teachings of the disclosure without departing from the essential scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A method comprising: providing electrical energy from an external source to a vehicle energy storage component until the vehicle energy storage component is charged to a threshold state of charge percentage; monitoring, using the controller, an external data source for occurrences of energy consumption events in at least one connected system; as well as The energy depletion event is responded to by charging the remaining portion of the vehicle energy storage component.

2. The method according to claim 1 also includes monitoring whether the vehicle energy consumption event still exists when the remainder of the vehicle energy storage component has been fully charged, and in response to the energy consumption event still existing, one of the following: consuming energy from the energy storage component while charging the vehicle energy storage component so that zero net current passes through the vehicle energy storage component, and disconnecting the vehicle energy storage component from the vehicle power system.

3. The method according to claim 2, wherein: Consuming energy from the vehicle energy storage component includes one of converting energy from the vehicle energy storage component into waste heat, operating a vehicle system or component, and providing energy from the vehicle energy storage component to at least one external device.

4. The method according to claim 3, wherein: Converting energy from the vehicle energy storage component to waste heat includes one of: operating a vehicle heating, ventilation and cooling (HVAC) system, spinning a misfire engine, and operating vehicle power electronics.

5. The method according to claim 4, wherein: Converting energy from the vehicle energy storage component into waste heat also includes absorbing waste heat in a vehicle battery such that the vehicle energy storage component operates as a radiator.

6. The method according to claim 4, wherein: Operating the vehicle HVAC system includes at least one of simultaneously operating heating and cooling portions of the vehicle HVAC system and simultaneously operating heating and cooling portions of a power electronics and vehicle energy storage component temperature control system.

7. The method according to claim 2, wherein: The energy consumption event is a fault in a connected energy storage bank, and wherein the connected energy storage bank is a charging power source for a charging operation.

8. The method according to claim 2, wherein: The energy consumption event is a negative energy rate from a power grid, and wherein the power grid is a charging power source for a charging operation.

9. The method according to claim 2, wherein: Consuming energy from the energy storage component includes increasing power draw from one or more vehicle component auxiliary loads, the one or more vehicle auxiliary loads including at least one of a cabin fan, an under-hood fan, a drive pump, an actuator, a resistive heater, a lamp, and an onboard computer module.

10. A vehicle comprising: a propulsion system having at least one electric motor powered by a vehicle energy storage component; a plurality of auxiliary systems configured to receive operating power from one of a vehicle energy storage component and a vehicle power system capable of receiving power from the vehicle energy storage component; a charger configured to interface with an external power source and provide power to the vehicle energy storage component; and A controller configured to execute the method according to any one of claims 1-9.

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