Method for controlling distributed dc-dc converter system

Abstract

In an embodiment, there is provided a method for controlling a plurality of converters coupled to a plurality of battery cells of a rechargeable energy storage system (RESS) and configured to supply current to other systems requiring current, the method includes: obtaining cell data about the plurality of cells via one or more sensors, the cell data including a state of charge of each of the plurality of cells; acquiring other system data related to the other system, wherein the other system data comprises the magnitude of current required by the other system; and according to instructions provided by the processor, controlling the plurality of converters based on both: battery cell data including a state of charge of each of the plurality of battery cells; and other system data including the magnitude of current of other systems.

Description

Technical Field

[0001] The technical field generally relates to platforms such as vehicles, and more particularly, to methods and systems for controlling direct current ("DC") to DC converter systems such as in vehicles. Background Art

[0002] Some of today's vehicles have a rechargeable energy storage system ("RESS"), such as a vehicle battery, that operates high voltage systems (such as the vehicle motor) as well as low voltage systems (such as the vehicle radio, seat heaters, etc.), and utilizes a DC to DC converter to supply voltage from the battery cell pack of the RESS. However, existing vehicles may not always provide optimal control of the converter, for example in terms of providing optimal balance for the battery cell pack and / or providing longevity for the converter.

[0003] Therefore, it is desirable to provide improved methods and systems for controlling converters for RESS, such as for vehicles.Furthermore, other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background. Summary of the invention

[0004] According to an exemplary embodiment, a method for controlling multiple converters is provided, wherein the multiple converters are coupled to multiple battery cells of a rechargeable energy storage system (RESS) and are configured to supply current to one or more other systems that require current, the method comprising: obtaining battery cell data about the multiple battery cells via one or more sensors, the battery cell data including a charge state of each of the multiple battery cells; obtaining other system data about the one or more other systems, including an amount of current required by the one or more other systems; and controlling the multiple converters based on the following two, according to instructions provided by a processor: the battery cell data, including the charge state of each of the multiple battery cells; and the other system data, including the amount of current of each of the one or more other systems.

[0005] Also in the exemplary embodiment, control of multiple converters includes: selecting, via a processor, a selected converter group among multiple converters and a selected battery cell group among multiple battery cells coupled to the selected converter group for providing current to one or more other systems; and selecting, via the processor, a current command for the magnitude of the current to be provided to the one or more other systems via the selected converter group and the selected battery cell group.

[0006] Also in the exemplary embodiment, the selected converter group and current commands are selected via the processor to facilitate balancing the state of charge of the plurality of battery cells.

[0007] Also in the exemplary embodiment, the method further includes obtaining converter data regarding operation of the plurality of converters; wherein the selected set of converters and the current command are further based on the converter data, the converter data further accounting for any unavailable converters and facilitating life of the plurality of converters.

[0008] Also in an exemplary embodiment, the steps of the method are performed within a vehicle that includes a RESS, including multiple battery cells and multiple converters, and also includes one or more sensors, processors, and one or more other systems, and wherein the multiple converters include direct current (DC) to direct current (DC) converters.

[0009] Also in the exemplary embodiment, the method further includes providing, via the processor, a supplemental command separate and apart from the current command for supplemental balancing of the plurality of battery cells.

[0010] Also in the exemplary embodiment, the method further includes adjusting the current command based on an available current reserve in addition to the prioritization of the one or more other systems, including based on respective relative criticalities of the one or more other systems.

[0011] In another exemplary embodiment, a system for controlling a plurality of converters is provided, the plurality of converters being coupled to a plurality of battery cells of a rechargeable energy storage system (RESS) and being configured to supply current to one or more other systems requiring current, the system comprising one or more sensors and a processor. The one or more sensors are configured to obtain battery cell data about the plurality of battery cells, the battery cell data comprising a state of charge of each of the plurality of battery cells. The processor is coupled to the one or more sensors and is configured to at least facilitate obtaining other system data about the one or more other systems, including the amount of current required by the one or more other systems; and according to instructions provided by the processor, control the plurality of converters based on the following two: battery cell data, including the state of charge of each of the plurality of battery cells; and the other system data, including the amount of current of each of the one or more other systems.

[0012] Also in the exemplary embodiment, the processor is further configured to facilitate controlling multiple converters by at least: selecting a selected converter group among the multiple converters and a selected battery cell group among the multiple battery cells coupled to the selected converter group for providing current to one or more other systems; and selecting a current command for the magnitude of current to be provided to one or more other systems via the selected converter group and the selected battery cell group; wherein the current command is implemented via the selected converter group among the multiple converters.

[0013] Also in the exemplary embodiment, the processor is further configured to facilitate at least selecting the selected converter group and the current command to facilitate balancing of the state of charge of the plurality of battery cells.

[0014] Also in the exemplary embodiment, the processor is further configured to at least facilitate obtaining converter data regarding operation of the plurality of converters; and also select the selected converter group and current commands based on the converter data in a manner that also accounts for any unavailable converters and benefits the life of the plurality of converters.

[0015] Also in the exemplary embodiment, the processor is further configured to facilitate at least providing supplemental commands for supplemental balancing of the plurality of battery cells separate and distinct from the current commands.

[0016] Also in the exemplary embodiment, the processor is further configured to facilitate at least adjusting the current command based on available current reserves, including based on respective relative criticalities of the one or more other systems, in addition to prioritization based on the one or more other systems.

[0017] In another exemplary embodiment, a vehicle is provided that includes a rechargeable energy storage system (RESS), one or more other systems, and a control system. The RESS includes a plurality of battery cells and a plurality of converters coupled to the plurality of battery cells and configured to supply current. One or more other systems require current and receive current from the RESS. The control system includes one or more sensors and a processor. The one or more sensors are configured to obtain battery cell data about a plurality of battery cells, the battery cell data including a state of charge of each of the plurality of battery cells. The processor is coupled to the one or more sensors and the plurality of converters, and is configured to at least facilitate obtaining other system data about the one or more other systems, including the amount of current required by the one or more other systems; and control the plurality of converters based on the following two according to instructions provided by the processor: battery cell data, including the state of charge of each of the plurality of battery cells; and the other system data, including the amount of current of each of the one or more other systems.

[0018] Also in the exemplary embodiment, the processor is further configured to facilitate controlling multiple converters by at least: selecting a selected converter group among the multiple converters and a selected battery cell group among the multiple battery cells coupled to the selected converter group for providing current to one or more other systems; and selecting a current command for the magnitude of current to be provided to the one or more other systems via the selected converter group and the selected battery cell group; and implementing the current command via the selected converter group among the multiple converters.

[0019] Also in the exemplary embodiment, the processor is further configured to facilitate at least selecting the selected converter group and the current command in a manner that facilitates balancing of the state of charge of the plurality of battery cells.

[0020] Also in the exemplary embodiment, the processor is further configured to at least facilitate obtaining converter data regarding operation of the plurality of converters; and select the selected converter group and current commands based also on the converter data taking into account any unavailable converters and facilitating the life of the plurality of converters.

[0021] Also in the exemplary embodiment, the processor is further configured to facilitate at least providing supplemental commands for supplemental balancing of the plurality of battery cells separate and distinct from the current commands.

[0022] Also in the exemplary embodiment, one or more of the plurality of converters includes a bidirectional converter, and provision of a supplemental command separate and apart from a current command is provided by the processor and implemented by the bidirectional converter for supplemental balancing of the plurality of battery cells.

[0023] Also in the exemplary embodiment, the processor is further configured to, in addition to the prioritization of the one or more other systems, at least facilitate adjusting the current command based on an available current reserve, including based on respective relative criticalities of the one or more other systems. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present disclosure will be described below in conjunction with the following drawings, wherein like reference numerals represent like elements, and wherein:

[0025] Figure 1 is a functional block diagram of a vehicle including a RESS and a control system for controlling the same and various other components according to an exemplary embodiment;

[0026] Figure 2 is a functional block diagram showing a RESS according to an exemplary embodiment, which includes a plurality of battery cell groups and a plurality of DC to DC converters and can be directed to Figure 1RESS implementation in a vehicle; and

[0027] Figure 3A and Figure 3B (also collectively referred to herein as "FIG. 3") includes a flow chart of a process for controlling a RESS according to an exemplary embodiment, and the process may be combined with Figure 1 Vehicles (including RESS and its control system) and Figure 2 RESS is achieved. DETAILED DESCRIPTION

[0028] The following detailed description is merely exemplary in nature and is not intended to limit the present disclosure or its application and uses. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.

[0029] Figure 1 A vehicle 100 is shown according to an exemplary embodiment. As described in further detail below, the vehicle 100 includes, among other components, a rechargeable energy storage system ("RESS") 101 and a control system 102. In various embodiments, the RESS 101 includes a plurality of battery cell groups 170 and a plurality of direct current to direct current (i.e., "DC" to "DC") converters 172, such as Figure 2 Also in various embodiments, the control system 102 controls the RESS 101, including optimizing the charge balance of the battery cell group 170 and the life of the RESS 101 (including its converter 172) by controlling the operation of the converter 172, according to Figure 3A and 3B The steps of process 300 are depicted in FIG. 1 and described in further detail below.

[0030] like Figure 1 As shown, the RESS 101 and the control system 102 are depicted as part of a vehicle 100 according to an exemplary embodiment. In various embodiments, the vehicle 100 includes an automobile, such as any of a plurality of different types of automobiles, such as a sedan, a four-wheeler, a truck, a sport utility vehicle (SUV), etc. In certain embodiments, the vehicle 100 may also include a motorcycle or other vehicle, such as an airplane, a spacecraft, a boat, etc., and / or one or more other types of mobile platforms (e.g., a robot and / or another mobile platform). In other embodiments, the RESS 101 and the control system 102 may alternatively be part of and / or coupled to any number of other types of platforms and / or other systems, whether mobile or non-mobile, such as buildings, infrastructure, and / or other platforms and / or other systems.

[0031] In the depicted embodiment, the vehicle 100 includes a body 104 disposed on a chassis 116. The body 104 substantially surrounds the other components of the vehicle 100. The body 104 and the chassis 116 may together form a frame. The vehicle 100 also includes a plurality of wheels 112. The wheels 112 are each rotationally coupled to the chassis 116 near a respective corner of the body 104 to facilitate movement of the vehicle 100. In one embodiment, the vehicle 100 includes four wheels 112, but this may vary in other embodiments (e.g., for trucks, motorcycles, and certain other vehicles).

[0032] The drive system 110 is mounted on a chassis 116 and drives wheels 112, for example, via shafts 114. In certain embodiments, the drive system 110 includes a propulsion system having a motor 113. In various embodiments, the drive system 110 including the motor 113 receives a high voltage from the RESS 101.

[0033] In various embodiments, in addition to providing high voltage to motor 113, RESS 101 also provides low voltage to one or more low voltage systems 111 of vehicle 100. In various embodiments, low voltage systems 111 may include, for example, one or more climate control systems, radio systems, seat heating systems, etc.

[0034] like Figure 1 As shown, in various embodiments, the vehicle also includes a braking system 106 and a steering system 108. In an exemplary embodiment, the braking system 106 controls the braking of the vehicle 100 using braking components that are automatically controlled via input provided by the driver (e.g., via a brake pedal) and / or via a control system (such as the control system 102 and / or one or more other control systems). Also in an exemplary embodiment, the steering system 108 controls the steering of the vehicle 100 via steering components that are controlled via input provided by the driver (e.g., via a steering wheel) and / or automatically controlled via a control system (such as the control system 102 and / or one or more other control systems).

[0035] exist Figure 1 In the illustrated embodiment, the control system 102 is coupled to the RESS 101, receives inputs therefrom, and controls its functions via control of the converter 172. Additionally, in certain embodiments, the control system 102 is coupled to one or more of the braking system 106, the steering system 108, the drive system 110, and / or the low pressure system 111, and in certain embodiments may also receive inputs from and / or control these additional systems. In various embodiments, the control system 102 may be configured as follows: Figure 3A and 3B The process 300 depicted in and as further described below in conjunction therewith provides these functions.

[0036] Likewise Figure 1 As shown, in various embodiments, the control system 102 includes a sensor array 120 and a controller 140, as described in more detail below.

[0037] In various embodiments, the sensor array 120 includes various sensors that obtain sensor data of the vehicle 100 for controlling the RESS 101 (including its converter 172) and other functions. In the depicted embodiment, the sensor array 120 includes one or more voltage sensors 130, current sensors 132, temperature sensors 134, state of charge sensors 136, brake sensors 137, and steering sensors 138. The sensors can be hardware-based sensors or virtual software equivalents.

[0038] In certain embodiments, the voltage sensor 130 measures the voltage of the RESS 101, including the voltages of its various battery cell groups 170. Also in certain embodiments, the current sensor 132 measures the current of the RESS 101, including the current of its battery cell groups 170. In various embodiments, the temperature sensor 134 measures the temperature of the RESS 101, including the temperature of its battery cell groups 170. Also in various embodiments, the state of charge sensor 136 measures the state of charge of the RESS 101, including the state of charge of its battery cell groups 170. Additionally, in various embodiments, the brake sensor 137 measures one or more parameters related to the brake system 106 (e.g., brake input, brake force, etc.), while the steering sensor 138 measures one or more parameters related to the steering system 108 (e.g., steering input, steering angle, etc.).

[0039] In various embodiments, the controller 140 is coupled to the sensor array 120 and receives sensor data therefrom. In various embodiments, the controller 140 is also coupled to the RESS 101, including the converter 172 for controlling it. In addition, in some embodiments, the controller 140 may also be coupled to one or more other systems of the vehicle 100, such as the braking system 106, the steering system 108, the drive system 110, and / or the low-voltage system, for example, to receive inputs therefrom and / or to control them.

[0040] In various embodiments, the controller 140 controls the operation of the converter 172, including with respect to the selective charging and discharging of different battery cell groups 170 via the converter 172 in order to optimize the balancing of the battery cell groups 170 and / or the life of the converter 172, as well as other potential functions of the vehicle 100. In various embodiments, the controller 140 provides these functions according to the steps of the process 300, which are described in Figure 3A and 3B and described in further detail below in conjunction therewith.

[0041] like Figure 1 As shown, in various embodiments, the controller 140 comprises a computer system (also referred to herein as computer system 140 ), and includes a processor 142 , a memory 144 , an interface 146 , a storage device 148 , and a computer bus 150 .

[0042] Processor 142 performs computational and control functions of controller 140 and may include any type of processor or multiple processors, a single integrated circuit such as a microprocessor, or any suitable number of integrated circuit devices and / or circuit boards that work in cooperation to accomplish the functions of a processing unit. During operation, processor 142 executes one or more programs 152 contained within memory 144 and, therefore, controls the general operation of controller 140 and the computer system of controller 140, typically in performing the processes described herein, such as Figure 3A and 3B The process 300 is described in detail below and is further described in conjunction with it.

[0043] The memory 144 can be any type of suitable memory, including various types of non-transitory computer-readable storage media. In some examples, the memory 144 is located and / or co-located on the same computer chip as the processor 142. In the depicted embodiment, the memory 144 stores the above-described program 152 and stored values ​​157 (e.g., lookup tables, thresholds, and / or other values ​​related to the control of the RESS 101).

[0044] The interface 146 allows, for example, communication from a system drive and / or another computer system to the computer system of the controller 140, and may be implemented using any suitable method and apparatus. In one embodiment, the interface 146 obtains various data from the sensor array 120 and other possible data sources. The interface 146 may include one or more network interfaces to communicate with other systems or components. The interface 146 may also include one or more network interfaces for communicating with a technician, and / or one or more storage interfaces for connecting to a storage device such as a storage device 148.

[0045] Storage device 148 may be any suitable type of storage device, including various different types of direct access storage and / or other memory devices. In an exemplary embodiment, storage device 148 includes a program product from which memory 144 may receive a program 152 that performs one or more embodiments of one or more processes of the present disclosure, such as Figure 3A and Figure 3BThe steps of process 300 are described in detail below and are further described in conjunction with the same. In another exemplary embodiment, the program product may be directly stored in and / or otherwise accessed by memory 144 and / or a disk (e.g., disk 156), such as referenced below.

[0046] The bus 150 is used to transfer programs, data, status and other information or signals between the various components of the computer system of the controller 140. The bus 150 can be any suitable physical or logical means of connecting the computer system and components. This includes, but is not limited to, direct hardwired connections, fiber optics, infrared and wireless bus technologies. During operation, the program 152 is stored in the memory 144 and executed by the processor 142.

[0047] It should be understood that while the exemplary embodiment is described in the context of a fully functional computer system, those skilled in the art will recognize that the mechanisms of the present disclosure can be distributed as a program product having one or more types of non-transitory computer-readable signal-bearing media for storing the program and its instructions and executing its distribution, such as a non-transitory computer-readable medium that carries the program and contains computer instructions stored therein for causing a computer processor (e.g., processor 142) to execute and perform the program.

[0048] Figure 2 According to an exemplary embodiment Figure 1 1 is a functional diagram of the RESS 101 , and the RESS 101 includes a plurality of battery cell groups 170 and a DC to DC converter 172 .

[0049] like Figure 2 As shown, in various embodiments, the RESS 101 includes a plurality of battery cell groups 170, such as a first battery cell group 170(1), a second battery cell group 170(2), and so on, until an "Nth" battery cell group 170(N). It should be understood that in different embodiments, the number of battery cell groups 170 may vary.

[0050] Likewise Figure 2 As depicted in FIG. 1 , and also in various embodiments, a plurality of DC to DC converters 172 are coupled to the battery cell group 170. In the depicted embodiment, the converters 172 include a first converter 172(1), a second converter 172(2), and so on, up to an “Nth” converter 172(N). Figure 2 As shown, in various embodiments, each converter 172 includes a DC to DC converter 172 and is coupled to one or more of the battery cell groups 170. It should be appreciated that the number of converters 172 may vary in different embodiments.

[0051] like Figure 2 As shown, in various embodiments, each converter 172 converts a direct current (DC) source from one or more battery cell groups 170 from one voltage to another voltage. In some embodiments, the current from one or more battery cell groups 170 can be selectively used in a priority order (such as for example, Figure 1 In some embodiments, the operation of different systems of the vehicle 100 is as follows. Figure 2 As depicted, from various converters ... 172 (N) (i.e., respectively "i o N", "i o 2", "i o N") can be aggregated into an aggregate current (i.e., "i s ”) for use by different systems. Also in some embodiments, the other current 176 can be stored and / or used for one or more other purposes, such as for rebalancing of the battery cell group 170 (e.g., as described below in conjunction with Figure 3A and 3B as described in more detail further on).

[0052] Figure 3A and 3B A flow chart of a process 300 for controlling a RESS according to an exemplary embodiment is provided. In various embodiments, the process 300 includes controlling a DC to DC converter of the RESS and may be combined with Figure 1 The vehicle 100 (including the RESS 101 and its control system 102) and Figure 2 RESS101 is implemented.

[0053] like Figure 3A As shown, process 300 begins at step 301. In one embodiment, process 300 begins when vehicle 100 is operating, such as during a current vehicle drive. In certain embodiments, process 300 may also begin when RESS 101 requires charging or discharging, and / or when RESS 101 and / or control system 102 are active and / or in a wake-up or "on" state. In an embodiment, the steps of process 300 are performed continuously during process 300.

[0054] In various embodiments, data is obtained (step 302). In various embodiments, from Figure 1The sensor array 120 obtains sensor data, including data about the battery cell group 170 (including its voltage, current, temperature, and state of charge) and other vehicle data (such as vehicle braking, steering, and / or propulsion). In various embodiments, data about the converters 172 (e.g., about the usage history of various converters 172) and other possible data about the vehicle 100, its operation, and / or conditions around the vehicle 100 may also be obtained.

[0055] In various embodiments, system loads are determined (step 303). Specifically, in various embodiments, the electrical loads of systems requiring electrical current (such as the low voltage system 111 of the vehicle 100) are determined. In various embodiments, these determinations are made via a processor (such as Figure 1 In addition, in various embodiments, the system load is utilized in step 303 described further below.

[0056] Additionally, in various embodiments, a determination is made of the required reserve for one or more systems for load changes (step 304). Specifically, in various embodiments, a determination is made of the required reserve for uncontrolled load changes of systems requiring current (e.g., the low voltage system 111 of the vehicle 100). In various embodiments, these determinations are made via a processor (such as a Figure 1 Also in various embodiments, these determinations are utilized in step 310, described further below.

[0057] In addition, in various embodiments, determinations are made regarding requests and reserves (step 306). Specifically, in various embodiments, these determinations are made via one or more processors (such as Figure 1 The processor 142 of step 320 uses information about the available reserve 308 determined regarding converter selection and power commands from step 320 to perform (as described in more detail further below).

[0058] In various embodiments, the determination of requests and reserves at step 306 includes output of allowed controller loads 322 for determining one or more controlled loads for each of converters 172. In various embodiments, these are determined via one or more processors such as Figure 1 determined by processor 142).

[0059] In addition, in various embodiments, a determination is made regarding the required reserve for the system (step 310). Specifically, in various embodiments, the determination of step 310 is performed via a processor (such as Figure 1The processor 142 of the vehicle 100 is based on the system required reserve for the load change of the system required current (such as the low voltage system 111 of the vehicle 100) as determined in step 304 and the request and reserve as determined in step 306.

[0060] In addition, in various embodiments, a determination is made regarding the power and reserve required by the system (step 312). Specifically, in various embodiments, for the current required by the system (such as the low voltage system 111 of the vehicle 100), based on the system load determined in step 303 and the system required reserve determined in step 310, a processor (such as Figure 1 The processor 142) determines the power and reserve required by the system.

[0061] In various embodiments, a determination is made regarding the number of converters (step 314). Specifically, in various embodiments, a processor (such as Figure 1 The processor 142) determines the Figure 1 and Figure 2 The number of converters 172 for current of the battery cell group 170 is determined to support the load requirements of the system required current (such as the low voltage system 111 of the vehicle 100), including the necessary reserves and maximum efficiency. In various embodiments, this determination is made based on the system required power and reserves determined in step 312. In various embodiments, the output of this determination, namely the number of converters 318, is utilized in step 320, as further described below.

[0062] Also in various embodiments, the output of step 312 (from the discussion above), namely the required power 316 (including reserves) determined in step 312 , is also used in step 320 (among various other inputs), also as further described below.

[0063] Reference now Figure 3B In various embodiments, as process 300 continues, various inputs are obtained at 323. Specifically, in various embodiments, the inputs to 323 include battery cell voltage 325, battery cell current 326, battery cell temperature 328, battery cell state of charge (SOC) 330 (along with other information 332, such as braking data, sensor data, and / or converter usage, among other possible information, in certain embodiments), which are used to determine the imbalance (step 334).

[0064] Specifically, in certain embodiments, during step 334, imbalances in one or more battery cell groups 170 are determined. In various embodiments, these determinations apply to one or more state of charge (SOC) imbalances with respect to relatively higher states of charge in certain battery cell groups 170 compared to other battery cell groups 170, based on converter-based battery cell grouping, etc. Also in various embodiments, these determinations are made by a processor (such as Figure 1 The processor 142 uses sensor data from the sensor array 120 to perform.

[0065] In various embodiments, the determination of step 334 results in balancing information 336 for each group of converters 172 that is used in both steps 320 and 344 , as described in greater detail further below.

[0066] In various embodiments, a diagnostic is performed at step 338. Specifically, in various embodiments, a processor (such as Figure 1 The processor 142) executes Figure 1 The process 300 may further include a step 338 process that includes a diagnostic of which of the converters 172 have failed, are not functioning properly, and / or have been recently utilized to such an extent that further use of such converters 172 is not currently recommended. In certain embodiments, if any of these conditions are met, such converters 172 will be considered unavailable during the current iteration of the process 300. Also in various embodiments, the diagnostic of step 338 results in an output that results in a list of unavailable converters 340, such as for use in steps 320 and 344 described below.

[0067] During step 320, in various embodiments, a determination is made regarding converter selection and power commands. Specifically, in various embodiments, Figure 1 One or more converters 172 are selected to convert current from one or more selected battery cell groups 170 to power one or more systems (e.g., Figure 1 The system of the vehicle 100, such as the low voltage system 111, is used to determine and implement one or more power commands regarding the amount of power or current that each converter 172 should draw from its corresponding battery cell group to maintain balance. In various embodiments, these determinations are made by a processor such as Figure 1 The processor 142 uses the balancing information 336 of step 334 and the list of unavailable converters 340 from step 338 as well as the required power 316 as determined in step 312 and the number of converters 318 as determined in step 314.

[0068] In some embodiments, the determination and / or selection of step 320 may vary. For example, in some embodiments, to maintain balance, the battery cell group 170 with the highest state of charge and the converter 172 coupled thereto may be utilized first. In some imbalances, time lags may be utilized in conjunction with battery cell group balancing. In some other embodiments, a cycling technique may be utilized to alternate the use of the converter 172 and the battery cell group 170 coupled thereto.

[0069] In various embodiments, the output of step 320 includes a measure of both available reserve 308 and converter command 346, both of which are processed via a processor such as Figure 1 In various embodiments, available reserve 308 is utilized in step 306, as described above.

[0070] Also in various embodiments, the converter commands 346 include commands for operation of the selected converter 172 and power commands for operation of the selected converter 172, the selected converter 172 being selected in step 320 for converting current from the selected corresponding battery cell group 170. In various embodiments, the converter selection and power commands are made by the processor to help maintain balance between the various battery cell groups 170, and further to enhance the operating life of the converter 172 based on the balance information 336, the unavailable converters 340, the required power 316, and the number of converters 318. Also in various embodiments, the converter commands 346 are utilized in step 348, as described below.

[0071] In various embodiments, during step 348, the converter commands 346 from step 320 are implemented. Specifically, in various embodiments, the selected converter 172 provides conversion for the current of the selected battery cell group 170 to provide power to one or more systems requiring current or power, such as Figure 1 In some embodiments, one or more additional actions may also be taken, as further described in more detail below in conjunction with step 354.

[0072] Referring back to step 334 and the resulting balancing information 336, as described above, in various embodiments, the balancing information 336 is also used in step 344. Specifically, in various embodiments, during step 344, supplemental balancing is performed. Figure 1 The invention also provides for current separation of the low voltage system 111 and separately performs additional (or supplementary) balancing of the battery cell group 170.

[0073] In some embodiments, during step 344, by Figure 2One or more converters 172 in Figure 2 The current is transmitted between the battery cell groups 170 and / or via Figure 2 Supplemental balancing may be performed by providing current to the battery cell group 170 and / or recovering current via the battery cell group 170 by one or more converters 172 (e.g., in some embodiments, via a vehicle current reservoir). Specifically, in some embodiments, if any converter 172 fails or is otherwise unavailable, converter-based balancing may not be performed properly, which may require secondary balancing. Additionally, in some embodiments, if battery cell balancing by varying converter loads is insufficient, secondary balancing may be applied in order to maintain overall battery pack balance. In some embodiments, supplemental balancing corresponds to, for example, Figure 2 In addition, in various embodiments, according to one or more processors (such as Figure 1 The processor 142 provides instructions to one or more of the converters 172 to perform supplemental balancing.

[0074] In various embodiments, the supplemental balancing of step 344 results in the processing of the data by one or more processors such as Figure 1 142) and is provided by one or more converters (such as Figure 1 and Figure 2 The battery cell balancing command 350 is implemented by one or more of the converters 172 of the embodiment of the present invention. In some embodiments, one or more additional actions may also be taken, as further described in more detail below in conjunction with step 354.

[0075] In various embodiments, one or more additional actions may be taken during step 354 (e.g., in addition to converter command 346 implemented by the converter in step 348 and in addition to cell balancing command 350 implemented in step 354). Specifically, in certain embodiments, the current or power provided to the low voltage system 111 may be prioritized and / or adjusted, such as temporarily adjusted as needed to save energy and / or power or maintain cell group balance and / or converter life, among other possible actions.

[0076] For example, in some embodiments, voltage loads to certain systems that can provide non-essential functions (e.g., a passenger seat heating system) may not be allowed, reduced, and / or delayed in certain circumstances (e.g., based on available voltage loads and / or reserves), but voltages for more critical functions (e.g., for vehicle braking and steering) may be fully allowed. Additionally, in some embodiments, voltage reserves may be established for such systems (including those with relatively lower priority) for use when available. Additionally, in some embodiments, one or more bidirectional converters 172 may be utilized, for example, to draw energy from the vehicle voltage bus as needed and place the energy in one or more battery cell groups 170 (e.g., if the state of charge of those battery cell groups 170 is low), and / or to help circulate from one battery cell group 170 to another battery cell group 170 (e.g., if the state of charge of one battery cell group 170 is high and the state of charge of another battery cell group 170 is low, etc.), as well as other possible actions.

[0077] In various embodiments, process 300 then terminates at step 356 .

[0078] Thus, methods, systems, and vehicles for controlling a DC to DC converter system are provided, such as, in certain embodiments, as part of a RESS of a vehicle. Specifically, in various embodiments, the methods and techniques described herein help maintain battery cell group stability and charge balance while maintaining the life of the converter. In various embodiments, these techniques help create margin in low voltage systems that require current or power, while also determining how to cycle loads between converters in a varying manner to achieve multiple goals, namely, maximizing converter efficiency, balancing the energy drawn from each battery cell segment, and providing the required stability and transient response at the low voltage output. In addition, in various embodiments, the methods and techniques also address converters with power limitations and faulty and / or unavailable converters, and adjust the sequencing accordingly (e.g., so that a faulty or unavailable converter is not utilized). Furthermore, in various embodiments, the disclosed methods and systems provide a secondary battery cell balancing mechanism in situations where the converter is insufficient to maintain battery cell balance, as well as other potential benefits.

[0079] It should be understood that the systems, vehicles, and methods may vary from those depicted in the figures and described herein. Figure 1 The vehicle 100 (including the RESS 101, the control system 102 and / or other components thereof) may be connected to Figure 1 It should also be understood that the RESS 101 and / or its components and / or its implementations may also be different from Figure 2 as described above and / or in combination with Figure 2 Similarly, it should be understood that the steps of process 300 may be similar to those of RESS 101 and / or its components and / or its implementations. Figure 3A and 3B The steps depicted in FIG. 300 may be different, and / or the various steps of process 300 may occur simultaneously and / or in a manner similar to that depicted in FIG. Figure 3A and 3B The processes may occur in an order different from that depicted in and / or described above in conjunction therewith.

[0080] Although at least one exemplary embodiment has been presented in the foregoing specific embodiments, it should be understood that there are a large number of variations. It should also be understood that one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. On the contrary, the foregoing specific embodiments will provide a convenient roadmap for implementing one or more exemplary embodiments for those skilled in the art. It should be understood that various changes may be made to the functions and arrangements of the elements without departing from the scope of the present disclosure as set forth in the attached claims and their legal equivalents.

Claims

1. A method for controlling a plurality of converters coupled to a plurality of battery cells of a rechargeable energy storage system (RESS) and configured to supply current to one or more other systems requiring the current, the method comprising: obtaining battery cell data about the plurality of battery cells via one or more sensors, the battery cell data including a state of charge of each battery cell in the plurality of battery cells; obtaining other system data about the one or more other systems, including an amount of electrical current required by the one or more other systems; as well as According to instructions provided by the processor, the plurality of converters are controlled based on: The battery cell data includes the state of charge of each battery cell in the plurality of battery cells; and The other system data includes the current amount of each of the one or more other systems.

2. The method of claim 1 , wherein the controlling of the plurality of converters comprises: selecting, via the processor, a selected group of converters among the plurality of converters and a selected group of battery cells among the plurality of battery cells coupled to the selected group of converters for use in providing the current to the one or more other systems; as well as A current command for a magnitude of the current to be provided to the one or more other systems via the selected converter group and the selected battery cell group is selected via the processor.

3. The method according to claim 2, wherein: The selected converter group and the current command are selected via the processor to facilitate balancing of the state of charge of the plurality of battery cells.

4. The method according to claim 3, further comprising: obtaining converter data regarding operation of the plurality of converters; Wherein the selected set of converters and the current commands are further based on the converter data, the converter data also takes into account any unavailable converters and facilitates the life of the plurality of converters.

5. The method according to claim 4, wherein: The steps of the method are performed within a vehicle, the vehicle including the RESS, including the plurality of battery cells and the plurality of converters, and also including the one or more sensors, the processor and the one or more other systems, and wherein the plurality of converters include direct current (DC) to direct current (DC) converters.

6. The method according to claim 3, further comprising: A supplemental command separate and apart from the current command is provided via the processor for supplemental balancing of the plurality of battery cells.

7. The method according to claim 2, further comprising: In addition to the prioritization of the one or more other systems, the current command is adjusted based on a reserve of the current available, including based on respective relative criticalities of the one or more other systems.

8. A system for controlling a plurality of converters coupled to a plurality of battery cells of a rechargeable energy storage system (RESS) and configured to supply current to one or more other systems requiring the current, the system comprising: one or more sensors configured to obtain battery cell data about the plurality of battery cells, the battery cell data including a state of charge of each of the plurality of battery cells; as well as a processor coupled to the one or more sensors and configured to at least facilitate: obtaining other system data about the one or more other systems, including an amount of electrical current required by the one or more other systems; as well as According to instructions provided by the processor, the plurality of converters are controlled based on: The battery cell data includes the state of charge of each battery cell in the plurality of battery cells; and The other system data includes the current amount of each of the one or more other systems.

9. The system of claim 8, wherein the processor is further configured to at least facilitate controlling the plurality of converters by: selecting a selected set of converters among the plurality of converters and a selected set of battery cells among the plurality of battery cells coupled to the selected set of converters for use in providing the current to the one or more other systems; and selecting a current command for a magnitude of current to be provided to the one or more other systems via the selected set of converters and the selected set of battery cells; in, The current command is implemented via a selected group of converters among the plurality of converters.

10. The system according to claim 9, wherein: The processor is further configured to facilitate at least selecting the selected converter group and the current command to facilitate balancing of the state of charge of the plurality of battery cells.

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