Disconnected wire fault detection independent of battery cell characteristics

Abstract

Aspects of the present disclosure relate to open wire fault detection independent of battery cell characteristics. A system may include an electronic control unit (ECU) and a battery monitoring circuit that generates an open lead ratio value for each battery cell in a battery. The battery monitoring circuit compares the open lead ratio value of each battery cell to a predetermined threshold, wherein the first battery cell and the second battery cell have respective open lead ratio values that do not exceed the predetermined threshold. The battery monitoring circuit determines whether the second battery cell has a real open wire condition based on a comparison between the open wire ratio value of the third battery cell and a predetermined threshold, and sends an indication of open wire fault detection of one or more battery cells to the ECU to transition the battery to a safe state.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 701,008, filed on September 30, 2024, entitled “OPEN WIRE FAULT DETECTIONAGNOSTIC TO BATTERY CELL CHARACTERISTICS,” the entire disclosure of which is expressly incorporated herein by reference. Background Technology

[0003] Batteries are commonly used as power sources, including for electric vehicles that include wheels driven by electric motors that receive power from the battery. This application relates to disconnected wire detection, and more specifically to disconnected wire fault detection independent of battery cell characteristics. Summary of the Invention

[0004] Electric vehicles with large batteries require safe operation for high-load applications such as electronics and motors, necessitating effective disconnected wire detection within the fault tolerance time interval (FTTI). Traditional detection methods rely on voltage measurements, which are influenced by the hardware design of the battery monitoring integrated circuit (BMIC). This can lead to inaccuracies when hardware changes occur, resulting in potential safety violations. Existing methods face the challenge of varying voltage behavior across different battery generations and hardware, leading to potential delays in detecting genuine faults or incorrectly identifying disconnected wires as false alarms, which could trigger inaccurate safety responses.

[0005] Implementations of this subject matter provide a disconnected wire detection algorithm that operates independently of battery cell voltage characteristics and hardware design. The disconnected wire detection algorithm evaluates the ratio of disconnected wires in adjacent strings (N, N+1, and N+2) to determine whether a string is truly disconnected, thereby minimizing false detections. In one or more other implementations, physical separation by the bus can affect detection accuracy. The disconnected wire detection algorithm conservatively estimates the state of strings near the bus to avoid overreaction in safety responses.

[0006] According to one or more aspects of this disclosure, a battery management system is provided, the battery management system including an electronic control unit (ECU) and a battery monitoring circuit configured to: determine a disconnected wire ratio value for each of a plurality of battery cells in the battery; determine that the first battery cell and the second battery cell have a potential disconnected wire condition based on a comparison between the disconnected wire ratio value of each of the first battery cell and the second battery cell in the plurality of battery cells and a predetermined threshold, wherein a disconnected wire ratio value not exceeding the predetermined threshold indicates a potential disconnected wire condition; determine whether a potential disconnected wire condition associated with the second battery cell corresponds to a real disconnected wire fault detection based on a comparison between the disconnected wire ratio value of a third battery cell in the plurality of battery cells and the predetermined threshold; and send an indication to the ECU of which battery cell in the plurality of battery cells is associated with a real disconnected wire fault detection, so as to transition the battery to a safe state.

[0007] According to one or more aspects of this disclosure, a method includes: determining a disconnected wire ratio value for each of a plurality of battery cells in a battery; comparing the disconnected wire ratio value of each of the plurality of battery cells with a predetermined threshold, wherein a first battery cell and a second battery cell among the plurality of battery cells have corresponding disconnected wire ratio values ​​not exceeding the predetermined threshold; determining whether a second battery cell has a true disconnected wire condition based on a comparison between the disconnected wire ratio value of a third battery cell among the plurality of battery cells and the predetermined threshold; and sending an indication to an electronic control unit of a vehicle regarding whether one or more of the plurality of battery cells are associated with a disconnected wire fault detection, so as to transition the battery to a safe state.

[0008] According to one or more aspects of this disclosure, a vehicle includes: one or more sensors; an electronic control unit (ECU); and a battery monitoring circuit configured to: determine a disconnected wire ratio value for each of a plurality of battery cells in the battery; determine that the first battery cell and the second battery cell have a potential disconnected wire condition based on the disconnected wire ratio value of each of the first battery cell and the second battery cell in the plurality of battery cells not exceeding a predetermined threshold; compare the disconnected wire ratio value of a third battery cell in the plurality of battery cells with the predetermined threshold to determine whether the second battery cell has an actual disconnected wire condition; and send an indication to the ECU for the detection of a disconnected wire fault associated with one or more of the plurality of battery cells to transition the battery to a safe state. Attached Figure Description

[0009] Certain features of the present subject matter are set forth in the appended claims. However, for purposes of explanation, several embodiments of the present subject matter are illustrated in the following figures.

[0010] Figure 1A and Figure 1B A schematic perspective side view illustrating an example embodiment of a vehicle with a battery pack according to various aspects of this disclosure is shown.

[0011] Figure 2 A schematic perspective side view illustrating another example implementation of a vehicle with a battery pack according to various aspects of this disclosure is shown.

[0012] Figure 3 A block diagram illustrating an example vehicle for detecting disconnected wire faults according to one or more specific embodiments of the subject matter is shown.

[0013] Figure 4 A block diagram of an example battery monitoring circuit according to one or more specific embodiments of the subject matter is shown.

[0014] Figure 5A and Figure 5B A schematic diagram of an example battery monitoring circuit according to one or more specific embodiments of the subject matter is shown.

[0015] Figures 6A to 6C A block diagram illustrating an example process for detecting a disconnected wire fault according to one or more specific embodiments of the subject matter is shown.

[0016] Figure 7 A flowchart illustrating an example process for performing a disconnected wire fault detection according to one or more specific embodiments of the subject matter is provided.

[0017] Figure 8 An example is an electronic system in which one or more specific implementations of the techniques of this subject matter can be implemented. Detailed Implementation

[0018] The detailed description set forth below is intended to describe various configurations of the subject matter, and not to represent only the configurations in which the subject matter can be practiced. The accompanying drawings are incorporated herein and form part of the detailed description. The detailed description includes specific details in order to provide a thorough understanding of the subject matter. However, the subject matter is not limited to the specific details set forth herein, and can be practiced using one or more other specific embodiments. In one or more specific embodiments, structures and components are shown in block diagram form to avoid confusion with the concepts of the subject matter.

[0019] In one or more specific implementations, electric vehicles utilize large batteries capable of powering various high-load applications requiring significant current, including automotive electronics, motors, drivetrains, heat pumps, and heating, ventilation, and air conditioning (HVAC) systems. For applications requiring high Automotive Safety Integrity Levels (ASIL), diagnosing disconnected wires between battery cells and monitoring circuitry within the fault tolerance time interval (FTTI) is necessary to facilitate the transition to a safe state.

[0020] Traditional disconnected wire detection algorithms are based on voltage measurements taken at different time intervals with and without pull-up or pull-down circuits. Some methods rely on the characteristic voltage behavior of battery cells with disconnected wires to detect and distinguish disconnected wire faults from genuine overvoltage or undervoltage conditions. The voltage behavior reflecting fluctuations when the cell string is disconnected can be significantly affected by the design of the BMIC hardware. Therefore, the detection logic will need to be adapted with each hardware change. Applying unmodified disconnected wire detection algorithms across different hardware designs can lead to false alarms or delayed detection of true alarms, potentially violating FTTI requirements for vehicle safety.

[0021] In one or more embodiments, the actual disconnection condition of a cell string can exhibit different behaviors across different battery cell generations and hardware. In some existing methods, if the high side of an odd-numbered cell becomes open, the voltage of both the affected odd-numbered cell and its adjacent (or neighboring) even-numbered cell will fluctuate above their overvoltage / undervoltage thresholds and remain above those thresholds. Conversely, if the high side of an even-numbered cell becomes open, the cell voltage will decay to zero. In one or more other embodiments, in some other methods of battery monitoring integrated circuit (IC) hardware, the voltage fluctuations of cells (whether even or odd) do not always exceed the overvoltage / undervoltage thresholds and can return to operating range.

[0022] These behaviors can lead to two main problems: a) delayed detection of actual disconnected conductors, which could result in a violation of FTTI; and b) false detection of conductors that are not disconnected. The system's response when one conductor is disconnected can differ from the case of multiple disconnected conductors. Multiple disconnected conductors may trigger more extreme safety-state responses, resulting in thrust loss, while a single disconnected conductor allows continued operation with limited performance. If only one conductor is disconnected, false detection of a second disconnected conductor may trigger a more significant safety-state response. Furthermore, delayed detection of disconnected conductors can compromise the safety concept. Therefore, reliable detection of multiple disconnected conductors is required to prevent unintended thrust loss.

[0023] This technical subject provides a disconnected wire detection algorithm that is independent of the voltage characteristics of a real disconnected wire, thus allowing the same algorithm to be applied across multiple programs with different unit chemistry. To determine whether each string, represented as string N, is disconnected, the disconnected wire detection algorithm evaluates the disconnected wire ratios of strings N, N+1, and N+2. If the ratio for string N drops below a disconnected wire threshold, string N is identified as disconnected.

[0024] The disconnected state of string N affects the disconnected wire ratio of the adjacent string N+1. To avoid incorrectly detecting string N+1 as disconnected, the disconnected wire detection algorithm checks the disconnected wire ratio of string N+2. If the ratio for string N+2 remains within the normal range (or greater than the disconnected wire threshold), it is concluded that string N+2 is not affected by string N+1, and therefore string N+1 is not considered disconnected. The disconnected wire detection algorithm processes all strings sequentially using a loop, where the last two strings are handled separately because there are no N+2 strings in those cases. This method prevents string N+1 from being incorrectly detected as disconnected and helps to accurately count disconnected wires, thus maintaining a count of one for string N, rather than incorrectly counting both strings N and N+1, thereby preventing overreaction as previously identified.

[0025] In one or more other implementations, if string N is truly disconnected and the bus separates strings N+1 and N+2, the behavior of the disconnected conductor ratio of string N+2 may not be useful for determining the state of string N+1 due to the physical separation by the bus. Therefore, the disconnected conductor detection algorithm may fail to detect the state of string N+1 and thus estimate string N+1 as truly disconnected. If only one string (adjacent to the string immediately preceding the bus) is truly disconnected, this conservative estimation may only lead to overreaction.

[0026] In one or more specific implementations, the term "string" refers to a series of battery cells and is used interchangeably with the term "cell" when discussing battery configurations. This applies to use cases where multiple battery cells are connected in series to form a string, and the terminology remains consistent throughout.

[0027] This technology differentiates itself from existing methods by making the disconnected wire detection algorithm independent of the battery monitoring IC hardware design. Competitive advantages of this technology include compatibility with various cell chemistry compositions and robust detection of disconnected wires in battery cells, enhancing overall battery safety. By making the disconnected wire detection algorithm independent of both hardware and cell chemistry, this technology supports scalability and reduces the development time of multiple programs. Furthermore, this technology results in more reliable disconnected wire detection, further improving battery safety.

[0028] Figure 1AThese are illustrations illustrating specific implementations of the movable device as described herein. Figure 1A In the example, the mobile device is implemented as a vehicle 100. As shown, the vehicle 100 may include one or more battery packs, such as battery pack 110. Battery pack 110 may be coupled to one or more electrical systems of the vehicle 100 to provide power to the electrical systems.

[0029] In one or more embodiments, vehicle 100 may be an electric vehicle having one or more electric motors that use electricity from battery pack 110 to drive the wheels 102 of vehicle 100. In one or more embodiments, vehicle 100 may also or alternatively include one or more chemically powered engines, such as gasoline engines or fuel cell-powered motors. For example, electric vehicles may be fully electric or partially electric (e.g., hybrid or plug-in hybrid). In various embodiments, vehicle 100 may be a fully autonomous vehicle capable of operating on roads without a human operator or driver, a partially autonomous vehicle capable of operating on some roads without a human operator or driver or capable of operating on roads under the supervision of a human operator, a driverless vehicle capable of operating on roads or other paths without any human occupants, or a human-operated (non-autonomous) vehicle configured for human operation.

[0030] exist Figure 1A In the example, vehicle 100 is implemented as a motor vehicle (e.g., an electric motor vehicle) having a battery pack 110. As shown, the battery pack 110 may include one or more battery modules 115, which may include one or more battery cells 120. Figure 1A As shown, the battery pack 110 may also or alternatively include one or more battery cells 120 directly mounted within the battery pack 110 (e.g., in a battery cell-battery pack configuration). In one or more embodiments, the battery pack 110 may not have any battery modules 115, but instead may have battery cells 120 directly mounted within the battery pack 110 (e.g., in a battery cell-battery pack configuration) and / or other battery devices installed within the battery pack 110. Vehicle battery packs may include multiple energy storage devices that can be arranged as battery modules or battery devices. Battery devices or modules may include unit components capable of being combined with other elements (e.g., structural frames, thermal management devices) that can protect the unit components from heat, shock, and / or vibration.

[0031] For example, battery cell 120 may be included in a battery, battery device, battery module, and / or battery pack to power components of vehicle 100. For example, the battery cell housing of battery cell 120 may be disposed in battery module 115, battery pack 110, battery array, or other battery device installed in vehicle 100.

[0032] In some embodiments, battery pack 110 may be combined with battery management device 114, which determines a disconnection wire ratio value for each of a plurality of battery cells (e.g., battery cell 120) in the battery (e.g., battery pack 110). Battery management device 114 may determine that a first and second battery cell among the plurality of battery cells has a potential disconnection wire condition based on a comparison between the disconnection wire ratio value of each battery cell among the plurality of battery cells and a predetermined threshold. In one or more embodiments, a disconnection wire ratio value not exceeding a predetermined threshold indicates a potential disconnection wire condition. Battery management device 114 may determine whether a potential disconnection wire condition associated with a second battery cell corresponds to a real disconnection wire fault detection based on a comparison between the disconnection wire ratio value of a third battery cell among the plurality of battery cells and a predetermined threshold. Battery management device 114 may send an indication to the electronic control unit of vehicle 100 of which battery cell among the plurality of battery cells is associated with a real disconnection wire fault detection, thereby transitioning battery pack 110 and / or vehicle 100 to a safe state.

[0033] As discussed in further detail below, battery cell 120 may be provided with a battery cell housing, which may be provided with any of a variety of external shapes. In some embodiments (e.g., for cylindrical or prismatic battery cells), the battery cell housing may be a rigid housing. In some embodiments, the battery cell housing may also be or alternatively shaped as a pouch or other flexible or stretchable housing for the battery cell. In various other embodiments, the battery cell housing may be provided with any other suitable external shape, such as a triangular external shape, a square external shape, a rectangular external shape, a pentagonal external shape, a hexagonal external shape, or any other suitable external shape. In some embodiments, battery pack 110 may not include modules (e.g., the battery pack may be module-free). For example, battery pack 110 may have a module-free or battery cell-battery pack configuration, wherein battery cells 120 are arranged directly into battery pack 110 without being assembled into battery modules 115. In one or more embodiments, vehicle 100 may include one or more busbars, electrical connectors, or other charge harvesting, current harvesting, and / or coupling components to supply power from battery pack 110 to various systems or components of vehicle 100. In one or more embodiments, vehicle 100 may include control circuitry such as power stage circuitry that can be used to convert DC power from battery pack 110 into AC power for one or more components and / or systems of vehicle (e.g., including one or more power outlets for vehicle and / or motors driving the wheels 102 of vehicle). The power stage circuitry may be located within vehicle 100 as part of battery pack 110 or separately from battery pack 110.

[0034] The vehicle 100 is implemented as a sport multi-purpose vehicle. Figure 1A The examples provided are merely illustrative. In one or more other embodiments, the vehicle 100 including the battery pack 110 may be implemented as a truck (e.g., an electric pickup truck). The vehicle 100 including the battery pack 110 may include a cargo storage area enclosed within the vehicle 100 (e.g., behind a row of seats in the vehicle's cabin). In other embodiments, the vehicle 100 may be implemented as another type of electric truck, electric van, electric car, electric motorcycle, electric scooter, electric bicycle, electric passenger vehicle, electric passenger or commercial truck, hybrid vehicle, aircraft, ship, and / or any other mobile device having the battery pack 110 (e.g., the battery pack is a battery pack or other battery device that powers the propulsion or drive components of the mobile device).

[0035] like Figure 1BAs shown, vehicle 100 may include a support structure, such as chassis 125 (e.g., frame, internal frame, or other support structure). Chassis 125 may support various components of vehicle 100. As shown, in some embodiments, chassis 125 may span the front portion 130 (e.g., hood or cover portion), central body portion 135, and rear portion 140 (e.g., luggage compartment, payload, or trunk portion) of vehicle 100. In one or more embodiments, battery pack 110 may be mounted on chassis 125 (e.g., within one or more of the front portion 130, central body portion 135, or rear portion 140). In one or more other embodiments, battery pack 110 may include one or more buses (e.g., one or more current collector elements) or be electrically coupled to one or more buses, wherein the buses may include conductive material to connect or otherwise electrically couple battery module 115 or battery cell 120 to other electrical components of vehicle 100 to provide power to various systems or components of vehicle 100.

[0036] exist Figure 1B In one example, vehicle 100 may include a cargo storage area enclosed within vehicle 100 (e.g., behind a row of seats in the passenger compartment of vehicle 100). In other embodiments, vehicle 100 may be implemented as an electric truck, another type of electric SUV, electric van, electric car, electric motorcycle, electric scooter, electric bicycle, electric passenger vehicle, electric passenger or commercial truck, hybrid vehicle, aircraft, ship, and / or any other mobile device having a battery pack 110 (e.g., a battery pack or other battery device that powers the propulsion or drive components of the mobile device).

[0037] Figure 2An example battery pack 110 is depicted. Battery pack 110 may include a plurality of battery cells 120 (e.g., directly mounted within battery pack 110, or mounted within batteries, battery devices, and / or battery modules 115, as described herein) and / or battery modules 115, and one or more conductive coupling elements for coupling the voltage generated by the battery cells 120 to power-consuming components such as the electrical system of building 180 and / or vehicle 100. For example, the conductive coupling elements may include internal connectors and / or contactors that couple the plurality of battery cells 120, battery devices, batteries, and / or battery modules 115 together within battery pack frame 205 to generate a desired output voltage for battery pack 110. Battery pack 110 may also include one or more external connection ports. As shown, battery pack 110 may include electrical contacts 203 (e.g., high-voltage connectors) through which external loads (e.g., vehicle 100) can be electrically coupled to the battery modules and / or battery cells within battery pack 110. For example, a power cable (e.g., cable / connector 106) may be connected between the electrical contact 203 and the electrical system of the vehicle 100 or building (not shown) to provide power to the vehicle 100 or building. In some aspects, the battery pack 110 may be connected to the battery management device 114 via the electrical contact 203.

[0038] As shown, the battery pack 110 may include a battery pack frame 205 (e.g., a battery pack housing or frame). For example, the battery pack frame 205 may house or enclose one or more battery modules 115 and / or one or more battery cells 120 and / or other battery pack components. In one or more embodiments, the battery pack frame 205 may include or form a shielding structure on its outer surface (e.g., its bottom and / or under one or more battery modules 115, battery devices, batteries and / or battery cells 120) to protect the battery modules 115, battery devices, batteries and / or battery cells 120 from external conditions (e.g., when the battery pack 110 is installed in a vehicle 100 and the vehicle 100 is traveling on rugged terrain such as off-road terrain, ditches, rocks, rivers, streams).

[0039] Figure 3 A block diagram illustrating an example vehicle 100 for detecting disconnected wire faults according to one or more embodiments of the subject matter is shown. However, not all depicted components are applicable in all embodiments, and one or more embodiments may include additional or different components in addition to those shown in the figures. Variations in the arrangement and type of components may be made without departing from the spirit or scope of the claims set forth herein. Additional components, different components, or fewer components may be provided.

[0040] Vehicle 100 may include a battery pack 110, a battery management device 114, and a battery monitoring circuit 308. The battery management device 114 may include one or more electronic control units (ECUs) 302. ECU 302 may include a processor 304 and a memory 306. In one or more embodiments, vehicle 100 may include a processor 304 and / or a memory 306 separate from the ECU 302. For example, vehicle 100 may not include an ECU 302 and may include a processor 304 as part or all of a separate semiconductor device. In one or more embodiments, vehicle 100 may include multiple ECUs 302, each controlling specific functions of vehicle 100.

[0041] Processor 304 may include suitable logic, circuitry, and / or code that enables the processing of data and / or control of the operation of vehicle 100. In this regard, processor 304 may be enabled to provide control signals to various other components of vehicle 100, such as, for example, battery management device 114. For example, battery management device 114 may receive signals from ECU 302 (e.g., from processor 304 of ECU 302), such as signals to trigger fault detection of a disconnected wire on battery pack 110. Processor 304 may also control the transfer of data between the various parts of vehicle 100. Processor 304 may also implement an operating system, such as a real-time operating system, or be capable of otherwise executing code to manage the operation of vehicle 100.

[0042] Memory 306 may include suitable logic, circuitry, and / or code enabling the storage of various types of information, such as received data, machine learning model data, user authentication data, and / or configuration information. Memory 306 may include, for example, random access memory (RAM), read-only memory (ROM), flash memory, and / or magnetic storage devices. In one or more embodiments, memory 306 may store identifiers and / or authentication information for one or more users to identify authorized users and / or authorized authentication devices of vehicle 100. Memory 306 may also store account information corresponding to authorized users for exchanging information between vehicle 100 and a remote server. Memory 306 may also store location data, including geographic locations predicted from historical routes. Memory 306 may also store measurement data associated with instances of disconnected wire fault detection performed on battery pack 110. Memory 306 may also store battery data, including the amount of time elapsed since the battery was last charged.

[0043] In one or more embodiments, one or more of the processor 304, memory 306, battery pack 110, battery management device 114, data source 308, ECU 302 and / or one or more portions thereof may be implemented in software (e.g., subroutines and code), in hardware (e.g., application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), programmable logic devices (PLDs), controllers, state machines, gated logic, discrete hardware components, or any other suitable device), and / or a combination of both.

[0044] In one or more implementations, there exists a potential failure mode in which a break may occur at any point in the battery pack 110, such as in a wiring harness, printed circuit board (PCB) trace, or within an integrated circuit (IC). Such a failure may result in the inability to sense battery cell voltage. This particular failure mode may be referred to as a “disconnected wire.” A disconnected wire may occur when the voltage sensing wire is disconnected at an unspecified location within the battery pack 110. Software can be used to detect this disconnection and elicit a corresponding response in the battery pack 110. If one or more battery cells 120 become disconnected or the wire breakage exceeds a certain threshold, the battery management device 114 may be unable to accurately estimate the state of the battery pack 110, potentially leading to safety hazards, range estimation problems, and a compromised user experience.

[0045] In one or more embodiments, the battery management device 114 may respond to a break based on the number of detected disconnected wires. For example, if the battery pack 110 contains 26 cells or 108 cells, the response (or transition to a safe state level) may vary based on the number of disconnected connections, depending on the configuration. In the case of a single break, the battery management device 114 allows the vehicle 100 to operate in a limited power or energy mode, enabling the user of the vehicle 100 to drive to a service station, but with reduced acceleration and range compared to normal operation. In the case of multiple breaks, the battery management device 114 may respond more aggressively by preventing the vehicle 100 from operating, initiating a controlled shutdown, and requiring the vehicle 100 to be towed to a service center for repair.

[0046] In one or more specific implementations, it is necessary to detect whether there is a break (disconnected wire) in the battery pack 110, and if so, to detect whether the break involves a single disconnected wire or multiple disconnected wires. The responsiveness level of the battery management device 114 to the user of the vehicle 100 (including user experience and the operating status of the vehicle 100) may vary depending on the number of disconnected wires detected.

[0047] In one or more embodiments, when battery cell 120 experiences a break, it may cause specific voltage behavior. For example, if the first cell in a series of connected battery cells fails, the voltage of that cell may drop below a threshold (e.g., 1.8 volts), which may be a defined undervoltage limit. In one or more other embodiments, the voltage of an adjacent cell (e.g., adjacent to the first cell) may rise above an overvoltage threshold (e.g., 4.2 volts). If the voltage of an adjacent cell remains elevated, battery management device 114 may infer that the preceding cell has an open circuit, thereby allowing battery management device 114 to ignore the overvoltage signal and prevent further diagnostic complications. The disconnected wire detection algorithm prevents an overreaction to erroneous overvoltage readings that would otherwise trigger a more severe system response.

[0048] In one or more embodiments, fault mode detection may be necessary to reduce the occurrence of unnecessary reactions. For example, a single disconnected wire may allow vehicle 100 to operate in a limited-power mode, but a real overvoltage condition may force battery management device 114 to disconnect battery pack 110 and shut down vehicle 100. In one or more other embodiments, disconnected wire detection algorithms may have limitations in detecting disconnected wire conditions as hardware configuration, cell chemistry, and voltage characteristics change. For example, instead of measuring cells that remain in a static undervoltage or overvoltage state, affected cells may exhibit oscillating voltage patterns, i.e., shifting in and out of their operating range. In one or more embodiments, this inconsistency in voltage behavior may pose an increasing challenge to conventional disconnected wire detection algorithms, affecting their reliance on consistent voltage readings to determine if a cell is faulty. The fluctuating nature of cell voltages in both the faulty cell and its neighboring cells may cause conventional disconnected wire detection algorithms to detect false alarms, as they may not be able to identify a clear fault condition. Given these new challenges, conventional disconnected wire detection algorithms may not be suitable for varying voltage patterns caused by changes in cell chemistry or hardware design.

[0049] The implementation of this subject matter provides a disconnected wire detection algorithm that is hardware-independent of the specific voltage characteristics of the battery pack 110. This disconnected wire detection algorithm allows for consistent performance across different hardware configurations and voltage characteristics, thereby reducing the need for custom algorithms for each program or hardware revision.

[0050] In one or more embodiments, battery management device 114 may determine a disconnection wire ratio value for each of a plurality of battery cells (e.g., battery cell 120) in a battery (e.g., battery pack 110). Battery management device 114 may determine that a first and second battery cell among the plurality of battery cells has a potential disconnection wire condition based on a comparison between the disconnection wire ratio value of each battery cell among the plurality of battery cells and a predetermined threshold. In one or more embodiments, a disconnection wire ratio value not exceeding a predetermined threshold indicates a potential disconnection wire condition. Battery management device 114 may determine whether a potential disconnection wire condition associated with a second battery cell corresponds to a real disconnection wire fault detection based on a comparison between the disconnection wire ratio value of a third battery cell among the plurality of battery cells and a predetermined threshold. Battery management device 114 may send an indication to ECU 302 of which battery cell among the plurality of battery cells is associated with a real disconnection wire fault detection, thereby transitioning battery pack 110 and / or vehicle 100 to a safe state.

[0051] Figure 4 A block diagram illustrating an example battery monitoring circuit according to one or more specific embodiments of the subject matter is shown. In one or more embodiments, a battery management device 114 can monitor the state of a cell (e.g., battery cell 120) by connecting a battery cell 120 to a voltage sensing circuit 402, wherein the voltage sensing circuit 402 may include an ASIC responsible for performing diagnostic measurements. Battery monitoring circuit 308 also includes cell connectors (referred to as cell taps) for the various battery cells 120 in the battery pack 110. For example, physical wires (e.g., cell tap 410) connect the battery cells 120 to battery monitoring circuit 308, which hosts the voltage sensing circuit 402. Battery monitoring circuit 308 includes a PCB that includes a main voltage trace 404 and a secondary voltage trace 406 electrically connecting the battery cells 120 to the voltage sensing circuit 402. Battery monitoring circuit 308 can monitor the voltage of each battery cell 120.

[0052] In one or more embodiments, the voltage sensor circuit 402 may include two redundant measurement pins (e.g., a primary measurement pin and a secondary measurement pin) that can measure the voltage of the same cell using two different methods. For example, if the primary measurement pin reports a cell voltage of 3.6 volts, the secondary measurement pin may report the same value. This redundancy contributes to reliability and safety. In one or more embodiments, these redundant measurements are performed outside the boundaries of the PCB (or battery monitoring circuit 308). In one or more embodiments, a single wire (e.g., cell tap 410) connects the battery cell 120 to the voltage sensing circuit 402; however, at the PCB boundary, the single tap 410 splits into two separate traces, namely a primary voltage trace 404 and a secondary voltage trace 406. The primary measurement pin may be connected to one trace, and the secondary measurement pin may be connected to the other trace, thus forming two independent paths to the voltage sensing circuit 402, which reads the voltage of the battery cell 120. Voltage characteristics can be continuously monitored for each cell in the battery pack 110. The voltage sensing circuit 402 can read the voltage of up to 16 cells, wherein the battery monitoring circuit 308 monitors their voltage levels for safety and operational purposes. In one or more embodiments, a fault mode in the battery pack 110 can be detected when the voltage sensing circuit 402 encounters a problem.

[0053] Figure 5A and Figure 5B A schematic diagram of an example battery monitoring circuit according to one or more specific embodiments of the present subject matter is illustrated. In one or more embodiments, each string in the battery pack 110 may have a positive terminal (+) and a negative terminal (-), wherein adjacent strings share a common wire. For example, the negative terminal of string 16 may be connected to the positive terminal of string 15 at node 512, and the negative terminal of string 15 may be connected to the positive terminal of string 14 at node 514, and so on.

[0054] When the battery pack 110 interacts with the voltage sensing circuit 402, a disconnected wire detection switch 502 and a resistor 508 are involved. This configuration is connected to an analog-to-digital converter (ADC) 510 for computational purposes. In one or more specific embodiments, a resistor 504 may be used as the input impedance of the ADC 510. Under normal conditions, when the disconnected wire detection switch 502 is open, current flows through this path, and the voltage across the resistor 504 is measured by the ADC 510. A capacitor 506 may be arranged between each measurement channel (e.g., across the positive terminal of the first string and the negative terminal of the second string adjacent to the first string).

[0055] In one or more embodiments, when the disconnected lead detection switch 502 is open, charge distribution flows through capacitor 506, thereby affecting the voltage measurement of the connected string. In one or more other embodiments, when the disconnected lead detection switch 502 is closed, most of the current bypasses the input impedance of the ADC and flows through the disconnected lead detection switch 502, resulting in a very small current flowing through resistor 504. Therefore, the voltage measured across the input resistance of the ADC (e.g., the voltage across resistor 504) becomes very small. In this respect, battery cell 120 is short-circuited with resistor 508, which has a much lower resistance compared to the input resistance of the ADS (or resistor 504).

[0056] In one or more specific implementations, the disconnected wire detection algorithm may take into account the charge distribution among connected strings. As more strings become disconnected (e.g., the disconnected wire detection switch 502 is turned off on each measurement channel), the battery monitoring circuit 308 determines a lower disconnected wire ratio value (e.g., below 0.7) due to this redistribution of charge across the measurement channels. If the disconnected wire detection switch 502 is not turned off, the charge will return directly to the starting cell, unaffected by other strings. This phenomenon helps to detect disconnected wire conditions across the measurement channels of the battery monitoring circuit 308 and take appropriate action based on charge readings.

[0057] In one or more specific implementations, a disconnected wire ratio calculation can be performed on the auxiliary measurement pin voltage. Specifically, the disconnected wire ratio is calculated by dividing the auxiliary measurement pin voltage (referred to as the "test voltage") when the disconnected wire detection switch 502 is closed by the auxiliary measurement pin voltage (referred to as the "baseline") when the disconnected wire detection switch 502 is open. The baseline represents the normal operating scenario, and the test voltage is measured when the disconnected wire detection switch 502 is closed to simulate a disconnected wire condition.

[0058] In one or more specific implementations, a baseline measurement is determined by evaluating the ratio of the auxiliary measurement pin test voltage to the auxiliary measurement pin baseline voltage. When the disconnected wire detection switch 502 is open, the baseline voltage for the auxiliary measurement pin can be measured, thereby capturing the auxiliary measurement pin voltage at that point. When the disconnected wire detection switch 502 is closed, a discharge occurs through the path in the form of voltage or current, thereby changing the measured voltage. This changed value represents the auxiliary measurement pin test voltage. The disconnected wire detection algorithm uses the ratio between the baseline voltage (measured with the disconnected wire detection switch 502 open) and the test voltage (measured after the disconnected wire detection switch 502 is closed) for its calculations.

[0059] The ratio obtained for a single string (or cell) indicates whether a wire is truly broken. In one or more embodiments, if the ratio is less than a predetermined threshold (e.g., 0.7), it indicates a potentially broken wire condition. In one or more other embodiments, if the ratio is greater than the predetermined threshold, the wire is not considered broken. In one or more embodiments, the predetermined threshold may be a fixed value. In one or more other embodiments, the predetermined threshold is a variable value.

[0060] Figures 6A to 6C A block diagram illustrating an example process for detecting a disconnected wire fault according to one or more embodiments of the subject matter is shown. In one or more embodiments, the battery management device 118 may perform a process 600 comprising seven cycles during which at least some or all of the programmed measurements and diagnostics for the battery cell 120 may be performed. These diagnostics may include reading the cell voltage, reading the cell temperature, and detecting a disconnected wire. In one or more other embodiments, additional diagnostic checks may be performed, such as detecting clock drift and verifying whether the reference voltage of the voltage sensing circuit 402 is within or outside the range. The process 600 may be distributed across seven cycles to facilitate comprehensive monitoring of the battery pack 110.

[0061] In cycle three (e.g., 610), cycle four (e.g., 620), and cycle five (e.g., 630), the detection of a broken wire can be specifically performed. In cycle three (e.g., 610), the detection of a broken wire can be specifically performed. Figures 5A to 5B Baseline measurements are obtained when the disconnected wire detection switch 502 is open (e.g., not conducting). Test measurements can be obtained for even-numbered and odd-numbered units, respectively, in loop four (e.g., 620) and loop five (e.g., 630). In one or more embodiments, units can be categorized as even or odd, where even-numbered units can be labeled 2, 4, 6, etc., and odd-numbered units can be labeled 1, 3, 5, etc., for monitoring up to 16 units by the battery monitoring circuit 308. In one or more embodiments, this categorization (and / or arrangement of labeled units) can be aligned with the ASIC architecture of the voltage sensing circuit 402, allowing for the flexibility to process all odd-numbered units or all even-numbered units together in a separate loop. After loop five (e.g., 630), data can be processed to determine which of the 16 strings are disconnected.

[0062] In one or more embodiments, subsequent cycles (e.g., cycles 6 and 7) may be used for additional diagnostics, such as temperature measurements, and the battery monitoring circuit 308 may continuously cycle through these cycles (e.g., 610, 620, 630) to maintain real-time monitoring. In one or more embodiments, the complete sequence of all seven cycles (e.g., process 600) requires a duration of approximately 800 milliseconds to complete. In one or more other embodiments, cycle three (e.g., 610), cycle four (e.g., 620), and cycle five (e.g., 630) may be responsible for disconnected wire detection, running approximately once every 800 milliseconds. In one or more embodiments, process 600 incorporates a debounce mechanism to prevent false alarms by confirming continuous detection of disconnected wires before escalating to the necessary response. For example, to confirm a disconnected wire fault detection, the battery monitoring circuit 308 may expect to see at least three consecutive positive disconnected wire detections in cycles 3 through 5 (e.g., in 610, 620, and 630). Upon receiving an indication of three positive disconnected wire detections, the wires are considered to be genuinely disconnected, and an appropriate response is triggered (e.g., battery pack 110 transitions to the corresponding safety state level).

[0063] To improve the accuracy of the disconnected wire detection algorithm, the battery monitoring circuit 308 can cycle through the detection process multiple times (cycles 3 to 5) to verify whether the overvoltage or undervoltage condition is due to a disconnected wire or a genuine voltage problem. This cyclic process can be configurable, and the battery monitoring circuit 308 can complete the verification within a predetermined time frame. If a genuine overvoltage or undervoltage event is detected, the battery monitoring circuit 308, in conjunction with the battery management device 114, can react within this time frame to prevent potential battery thermal events. The decision-making process (regardless of whether the problem is a genuine disconnected wire or an actual voltage fault) is configured to occur within this predetermined time frame.

[0064] This timeframe can be programmed, at least in part, based on predefined safety requirements associated with vehicle 100, and allows battery monitoring circuit 308 to perform approximately three to four iterations, depending on the number of operations adapted within the predetermined timeframe. In one or more embodiments, when battery monitoring circuit 308 detects a potential disconnected wire condition in loop five (e.g., 630), it proceeds through feedback loop 650 and returns to loop three (e.g., 610), bypassing loop six (e.g., 660). Feedback loop 650 can be repeated until the disconnected wire detection is verified as a genuine disconnected wire fault detection. After three consecutive detections in loops three through five (e.g., 610 through 630), battery monitoring circuit 308 proceeds to loop six (e.g., 660). This process helps distinguish between false detections caused by a disconnected wire and genuine overvoltage or undervoltage events, as the battery management device 114 may react differently to each.

[0065] In one or more embodiments, loop three (e.g., 630) includes multiple operations performing a disconnected wire detection algorithm. For example, a first operation 632 includes generating a disconnected wire ratio value based on baseline voltage measurements and test voltage measurements. In another example, a second operation 634 includes comparing the disconnected wire ratio value with a predetermined threshold (e.g., a disconnected wire detection threshold). In another example, a third operation 636 includes ignoring strings (or cells) not considered to have potential disconnected wire conditions. In another example, a fourth operation 638 includes an incrementing counter that tracks the number of instances of potential disconnected wire conditions detected for a corresponding string (or cell). In another example, a fifth operation 640 includes classifying potential disconnected wire conditions for a corresponding string (or cell) as mature disconnected wire detection (or true disconnected wire fault detection). In another example, a sixth operation 642 includes evaluating strings (or cells) to see which strings (or cells) can be skipped or replaced. In another example, a seventh operation 644 includes transferring data associated with the disconnected wire fault detection to a storage device.

[0066] In one or more embodiments, for a first scenario 690 in which string 2 670 (denoted as "N") is actually disconnected, the battery monitoring circuit 308 transitions through different operations (e.g., 632 to 644) in loop five (e.g., 630). At the first operation 632, the battery monitoring circuit 308 calculates a disconnected wire ratio value by comparing a baseline voltage value of the string under test with a test voltage value of the string under test, which is determined in loop three (e.g., 610) and loop four (e.g., 620), respectively. In one or more embodiments, for strings that are not disconnected (or do not have a potential disconnected wire condition), the calculated disconnected wire ratio value may be greater than a predetermined threshold (e.g., greater than 0.7). If the string is disconnected (or has a potential disconnected wire condition), such as string 2 670 in this case, the disconnected wire ratio value may not exceed a predetermined threshold (e.g., less than 0.7). In one or more other embodiments, if the disconnected wire ratio of adjacent strings (e.g., string 3 672, also denoted as "N+1") is also no greater than a predetermined threshold (e.g., no more than 0.7), then the battery monitoring circuit 308 cannot rely solely on these two disconnected wire ratio values ​​to determine which string (e.g., string 2 670 and / or string 3 672) is truly disconnected. In one or more embodiments, if only the disconnected wire ratio of these two strings is considered, the disconnected wire detection algorithm may incorrectly indicate that both string 2 670 and string 3 672 are disconnected, implying a more serious situation with multiple disconnected strings.

[0067] Implementations of this subject matter utilize a broken wire detection algorithm configured to distinguish between a single broken string and multiple broken strings to address this challenge, as the system response can depend on the number of strings detected as having potential broken wire conditions. By observing the impact on neighboring strings, the broken wire detection algorithm can distinguish between actual broken strings and strings affected by neighboring broken strings. In one or more embodiments, for a single string having a potential broken wire condition, the system response may allow the user (or driver) of vehicle 100 to continue driving vehicle 100. In one or more other embodiments, for multiple strings having potential broken wire conditions, the system response may be more severe, where the user of vehicle 100 may not be allowed to continue driving vehicle 100.

[0068] In the first operation 632, the battery monitoring circuit 308 generates disconnected wire ratio values ​​for series 2 670 (denoted as "N"), series 3 672 (denoted as "N+1"), and series 4 674 (denoted as "N+2"). For example, the disconnected wire ratio value for series 2 670 is approximately 0.023, and the disconnected wire ratio value for series 3 672 is approximately 0.034. In the second operation 634, the disconnected wire ratio value for series 2 670 is compared with a predetermined threshold (e.g., 0.7) to see if it does not exceed the predetermined threshold. In this example, series 2 670 is marked as true because its disconnected wire ratio value does not exceed the predetermined threshold. Similarly, the disconnected wire ratio value for series 3 672 is compared with the predetermined threshold and is marked as true because its disconnected wire ratio value also does not exceed the predetermined threshold. In one or more other embodiments, the broken wire ratio value generated for string 4 674 at the first operation 632 can be compared with a predetermined threshold at the second operation 634. In one example, string 4 674 is marked as false at the second operation 634 because its broken wire ratio value is determined to exceed the predetermined threshold. Figure 6B and Figure 6C As illustrated, string 3 672 is adjacent to string 2 670 and string 4 674, and string 4 674 is not adjacent to string 2 670.

[0069] In one or more specific implementations, the battery monitoring circuit 308 may temporarily ignore string 3 672 because its broken wire ratio value appears to be affected by potential broken wire conditions in string 2 670. This is due to the physical wiring connections between adjacent strings (as referenced). Figures 5A to 5BAs described, string 3 672 may be affected by a potential disconnected wire condition in string 2 670, and therefore its disconnected wire ratio value may be marked at the third operation 636 to be ignored in subsequent operations (e.g., operations 638 to 642). For example, each string in battery pack 110 may have a positive terminal and a negative terminal, where adjacent strings share a common wire. In this example, the negative terminal of string 2 670 may be connected to the positive terminal of string 3 672. This process may be repeated iteratively by battery monitoring circuit 308 multiple times (e.g., approximately three times), after which battery monitoring circuit 308 may re-examine string 3 672 to confirm whether it is truly disconnected. If string 3 672 is later confirmed to be truly disconnected, then string 3 672 may no longer be ignored by battery monitoring circuit 308. Otherwise, string 3 672 may remain ignored, and string 2 670 becomes the only string identified as truly disconnected. In one or more specific implementations, serial line 4 674 may remain unaffected by potential disconnected wire conditions in serial line 2 670 because serial line 4 674 is not physically connected (or directly connected) to serial line 2 670. In this respect, serial line 4 674 may not be temporarily ignored at third operation 636, but remains available for subsequent operations. Third operation 636 prevents an unnecessary response to serial line 3 672 when the real problem lies with serial line 2 670.

[0070] At the fourth operation 638, after each broken wire ratio value check, the counter mechanism may increment. For string 2 670, the counter mechanism associated with string 2 670 may reach count three after at least three iterations through loops 3 to 5 (e.g., 610 to 630), thereby confirming that the potential broken wire condition of string 2 670 corresponds to a real broken wire fault detection, while the counter mechanism associated with string 3 673 may remain at count zero after at least three iterations through loops 3 to 5, thereby indicating that string 3 672 may not have been marked as a real broken wire (e.g., the potential broken wire condition of string 3 672 does not correspond to a real broken wire fault detection). For string 4 674, the counter mechanism associated with string 4 674 may remain at count zero after at least three iterations through loops 3 to 5, thereby confirming that string 4 674 is not a real broken wire.

[0071] At the fifth operation 640, after the counter mechanism associated with string 2 670 reaches the maximum count for verification, string 2 670 is classified as a mature broken wire detection (or a true broken wire fault detection). For strings 3 672 and 4 674, these two strings did not reach the maturity level required to be classified as true broken wire fault detection because their corresponding counts remain zero. At the sixth operation 642, after each iteration, strings 2 670 and 3 672 can be ignored and replaced, while string 4 674 is skipped for evaluation. At the seventh operation 644, the broken wire ratio value for each string (e.g., 670 to 674) can be copied to a storage device (e.g., memory 306).

[0072] In one or more specific embodiments, for a second scenario 692 in which bus 680 is located between two strings (e.g., string 678 (denoted as "N+1") and string 7 682 (denoted as "N")) in battery pack 110, bus 680 can be used as a resistive physical connection between multiple cells. The placement of bus 680, which separates the positive terminal of string 678 and the negative terminal of string 7 682, ensures that these terminals are not in the same physical location (as shown in reference ). Figures 5A to 5B (As described). In one or more embodiments, bus 680 may introduce a micro-resistance between unit connections. This resistance can be taken into account during the detection process performed by battery monitoring circuit 308, particularly when dealing with adjacent string connections (such as string 678 and string 782). Depending on the physical configuration, battery monitoring circuit 308 may assess whether voltage fluctuations between these strings are caused by a true open wire condition or by external factors such as shared resistive elements. This configuration of bus 680 may affect string 678 such that if string 5676 (denoted as "N") is a true open wire, the open wire ratio value for string 678 may be affected. In one or more embodiments, it may be impossible to rely on the open wire ratio value of string 782 to determine whether string 678 is a true open wire because the terminals between string 678 and string 782 are not physically connected. In one or more other embodiments, this may introduce limitations in detecting whether string 678 is a true open wire or is only affected by the condition of string 5676. For example, the presence of bus 680 may prevent N+2 checks from fully verifying the open wire detection algorithm.

[0073] In one or more specific implementations, in the second scenario 692, the battery monitoring circuit 308 can conservatively determine that string 678 is actually disconnected. This limitation may only affect one string located adjacent to bus 680 in the battery pack 110, thus reducing the likelihood of it occurring. If the occurrence involves limitations on multiple strings having potentially disconnected wire conditions, the battery monitoring circuit 308 may already be operating in a multi-cell disconnected wire detection scenario, and the system response may remain the same.

[0074] In one or more other embodiments, the battery monitoring circuit 308 may execute a disconnected wire detection algorithm, while N is close to the battery cell (e.g., Figure 1A When considering the total number of battery cells 120, the absence of cell N+2 is taken into account. In one or more embodiments, with 16 cells in battery pack 110, cell N+2 may be unavailable when N equals 15. For these situations, battery monitoring circuit 308 can adjust the disconnected wire detection algorithm by processing these cells individually. For N equals 15, battery monitoring circuit 308 may employ a method to detect disconnected wires without relying on cell N+2. When detecting a disconnected wire in string 16, the disconnected wire detection algorithm may not perform the N+2 check because a 17th cell is absent. In one or more embodiments, the process during loop five (e.g., 630) may include a loop iterating from string 1 to string 14, and for strings 15 and 16, battery monitoring circuit 308 may perform individual checks without referring to string N+2. In one or more other embodiments, for N equals 16, the last cell may be connected to the supply voltage, and its behavior when truly disconnected may differ from other cells. For example, if string 16 is actually disconnected, abnormal behavior may occur in battery pack 110, such as all strings appearing to have broken wires. Because the 16th unit can be configured to power the voltage sensing circuit 402 itself, if it has broken wires, the voltage sensing circuit 402 may not be powered and may not perform measurements. This condition can be detected by ECU 302, as it will be unable to communicate with the voltage sensing circuit 402.

[0075] Figure 7 A flowchart illustrating an example process 700 for performing a disconnected wire fault detection according to one or more specific embodiments of the subject matter is provided. For illustrative purposes, this document primarily refers to... Figures 1A to 1B The process 700 is described using the vehicle 100 and / or its various components. However, the process 700 is not limited to... Figures 1A to 1B The means of transport 100, and one or more steps (or operations) of process 700 may be performed by the means of transport 100 and / or other suitable mobile devices, equipment, or systems, or by one or more other structural components. Further for illustrative purposes, some steps of process 700 are described herein as occurring sequentially or linearly. However, multiple steps of process 700 may occur in parallel. Moreover, the steps of process 700 need not be performed in the order shown, and / or one or more steps of process 700 need not be performed and / or may be replaced by other operations.

[0076] At step 702, the battery monitoring circuit 308 can determine the disconnected wire ratio value for each of the plurality of battery cells in the battery.

[0077] At step 704, the battery management circuit 308 can compare the disconnected wire ratio value of each of the plurality of battery cells with a predetermined threshold.

[0078] At 706, battery management circuitry 308 determines whether the disconnected wire ratio of each of the first battery cell and the second battery cell in the plurality of battery cells exceeds a predetermined threshold. In one or more embodiments, a disconnected wire ratio not exceeding the predetermined threshold indicates a potential disconnected wire condition. If the disconnected wire ratio exceeds the predetermined threshold, process 700 proceeds to step 712. Otherwise, process 700 proceeds to step 708.

[0079] At step 708, the battery monitoring circuit 308 can determine that the first and second battery cells among the plurality of battery cells have a potential disconnected wire condition.

[0080] At step 710, the battery monitoring circuit 308 compares the disconnected wire ratio of the third battery cell among the plurality of battery cells with a predetermined threshold. If the disconnected wire ratio exceeds the predetermined threshold, process 700 proceeds to step 712. Otherwise, process 700 proceeds to step 714.

[0081] At 712, the battery monitoring circuit 308 can determine that the battery cell does not correspond to a true disconnected wire fault detection based on whether the disconnected wire ratio of the battery cell itself exceeds a predetermined threshold or the disconnected wire ratio of an adjacent cell (e.g., a third battery cell) exceeds a predetermined threshold.

[0082] At 714, the battery monitoring circuit 308 can determine, based on the determination that the disconnected wire ratio of the third battery cell exceeds a predetermined threshold, a potential disconnected wire condition associated with the second battery cell corresponds to a real disconnected wire fault detection.

[0083] At 716, the battery monitoring circuit 308 can send an indication to the ECU of which of the multiple battery cells is associated with a real disconnected wire fault detection, so that the battery can be switched to a safe state.

[0084] Figure 8 Example electronic systems 800 are illustrated, which can be used to implement various aspects of this disclosure. Electronic system 800 may be used to provide reference to Figures 1 to... Figure 7The features described and the processes performed with reference to these accompanying drawings may be part of any electronic device and / or include, but are not limited to, vehicles, computers, servers, smartphones, and wearable devices. Electronic system 800 may include various types of computer-readable media and interfaces for various other types of computer-readable media. Electronic system 800 includes persistent storage device 802, system memory 804 (and / or buffers), input device interface 806, output device interface 808, sensor 810, ROM 812, processing unit 814, network interface 816, bus 818, and / or subsets and variations thereof.

[0085] Bus 818 collectively represents the numerous internal devices and / or components of electronic system 800 that are communicatively connected (such as those mentioned above). Figure 4 All systems, peripherals, and chipset buses of any component in the vehicle 100 under discussion. In one or more embodiments, bus 818 communicatively connects one or more processing units 814 to ROM 812, system memory 804, and persistent storage device 802. From these various memory units, one or more processing units 814 retrieve instructions to be executed and data to be processed in order to perform the processes disclosed in this subject matter. In different embodiments, one or more processing units 814 may be a single processor or a multi-core processor. In one or more embodiments, one or more processing units 814 may be included on ECU 204, such as in the form of processor 206.

[0086] ROM 812 stores static data and instructions required by one or more processing units 814 and other modules of electronic system 800. On the other hand, persistent storage device 802 can be a read-write memory device. Persistent storage device 802 can be a non-volatile memory cell that stores instructions and data even when electronic system 800 is powered off. In one or more embodiments, mass storage devices (such as magnetic disks or optical disks and their corresponding disk drives) can be used as persistent storage device 802.

[0087] In one or more embodiments, a removable storage device (such as a flash drive and its corresponding solid-state device) may be used as persistent storage device 802. Similar to persistent storage device 802, system memory 804 may be a read-write memory device. However, unlike persistent storage device 802, system memory 804 may be volatile read-write memory, such as RAM. System memory 804 may store any of the instructions and data that one or more processing units 814 may need during operation. In one or more embodiments, the processes disclosed in this subject matter are stored in system memory 804, persistent storage device 802, and / or ROM 812. From these various memory units, one or more processing units 814 retrieve instructions to be executed and data to be processed in order to execute the processes of one or more embodiments.

[0088] Persistent storage device 802 and / or system memory 804 may include one or more machine learning models. Machine learning models (such as those described herein) are typically used to form predictions, solve problems, identify objects in image data, and so on. For example, the machine learning model described herein can be used to predict the thermal demand of a vehicle's battery pack along a specific section of the vehicle's route. Various specific implementations of the machine learning model are possible. For example, the machine learning model may be a deep learning network, a transformer-based model (or other attention-based model), a multilayer perceptron or other feedforward network, a neural network, etc. In various examples, the machine learning model can be more adaptive because these models can be improved over time by retraining the machine learning model as additional data becomes available.

[0089] Bus 818 is also connected to input device interface 806 and output device interface 808. Input device interface 806 enables a user to communicate information and select commands to the electronic system 800. Input devices that can be used with input device interface 806 may include, for example, an alphanumeric keypad, a touchscreen, and pointing devices. Output device interface 808 enables the electronic system 800 to communicate information to the user. For example, output device interface 808 can provide a display of an image generated by the electronic system 800. Output devices that can be used with output device interface 808 may include, for example, printers and display devices such as liquid crystal displays (LCDs), light-emitting diode (LED) displays, organic light-emitting diode (OLED) displays, flexible displays, flat panel displays, solid-state displays, projectors, or any other device for outputting information.

[0090] One or more embodiments may include a device that acts as both an input device and an output device, such as a touchscreen. In these embodiments, the feedback provided to the user can be any form of sensory feedback, such as visual feedback, auditory feedback, or tactile feedback; input from the user can be received in any form, including sound input, voice input, or tactile input.

[0091] Bus 818 is also connected to sensor 810. Sensor 810 may include a position sensor that can be used to determine the device's location based on positioning technologies. For example, the position sensor may provide one or more of GNSS positioning, wireless access point positioning, cellular phone signal positioning, Bluetooth signal positioning, image recognition positioning, and / or inertial navigation systems (e.g., via motion sensors such as accelerometers and / or gyroscopes). In one or more embodiments, sensor 810 may be used to detect the movement, travel, and orientation of electronic system 800. For example, the sensor may include an accelerometer, a rate gyroscope, and / or other motion-based sensors. Sensor 810 may include one or more biometric sensors and / or image sensors for authenticating users.

[0092] Bus 818 also couples electronic system 800 to one or more networks and / or one or more network nodes via one or more network interfaces 816. In this way, electronic system 800 can be part of a computer network, such as a local area network or a wide area network. Any or all components of electronic system 800 may be used in conjunction with the disclosure of this subject matter.

[0093] Specific embodiments within the scope of this disclosure may be implemented in part or in whole using a tangible computer-readable storage medium (or a plurality of tangible computer-readable storage media of one or more types) that encodes one or more instructions. The tangible computer-readable storage medium may also be non-transitory in nature.

[0094] Computer-readable storage media can be any storage medium that can be read, written, or otherwise accessed by general-purpose or special-purpose computing devices, including any processing electronics and / or processing circuitry capable of executing instructions. For example, but not limited to, computer-readable media can include any volatile semiconductor memory, such as RAM, DRAM, SRAM, T-RAM, Z-RAM, and TTRAM. Computer-readable media can also include any non-volatile semiconductor memory, such as ROM, PROM, EPROM, EEPROM, NVRAM, flash memory, nvSRAM, FeRAM, FeTRAM, MRAM, PRAM, CBRAM, SONOS, RRAM, NRAM, track memory, FJG, and Millipede memory.

[0095] Furthermore, computer-readable storage media may include any non-semiconductor memory, such as optical disc storage, magnetic disk storage, magnetic tape, other magnetic storage devices, or any other medium capable of storing one or more instructions. In one or more embodiments, the tangible computer-readable storage medium may be directly coupled to a computing device, while in other embodiments, the tangible computer-readable storage medium may be indirectly coupled to a computing device, for example, via one or more wired connections, one or more wireless connections, or any combination thereof.

[0096] Instructions can be directly executable or can be used to develop executable instructions. For example, instructions can be implemented as executable or non-executable machine code, or as instructions in a high-level language that can be compiled to produce executable or non-executable machine code. Furthermore, instructions can be implemented as data or may include data. Computer executable instructions can also be organized in any format, including routines, subroutines, programs, data structures, objects, modules, applications, applets, functions, etc. As will be recognized by those skilled in the art, details including, but not limited to, the number, structure, sequence, and organization of instructions can vary significantly without altering the underlying logic, functionality, processing, and output.

[0097] While the above discussion primarily concerns microprocessors or multi-core processors that execute software, one or more specific implementations are executed by one or more integrated circuits such as ASICs or FPGAs. In one or more implementations, such integrated circuits execute instructions stored on the circuit itself.

[0098] Unless otherwise specified, elements mentioned in the singular are not intended to mean one and only one, but rather one or more. For example, a “one” module can refer to one or more modules. Without further constraints, elements beginning with “a,” “an,” “the,” or “the” do not exclude the presence of additional identical elements.

[0099] Titles and subheadings (if any) are used for convenience only and do not limit this disclosure. The use of the word "exemplary" is intended as an example or illustration. With regard to the scope of use of terms such as "includes" or "has," such terms are intended to be inclusive in a manner similar to "includes," as understood when "includes" is used as a transitional term in the claims. Relational terms such as "first" and "second" can be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between these entities or actions.

[0100] Phrases such as "aspect," "the aspect," "on the other hand," "some aspects," "one or more aspects," "one implementation," "the implementation," "another implementation," "some implementations," "one or more implementations," "an implementation scheme," "the implementation scheme," "another implementation scheme," "some implementation schemes," "one or more implementation schemes," "a configuration," "the configuration," "another configuration," "some configurations," "one or more configurations," "the subject matter," "disclosure," "this disclosure," other variations thereof, and similar phrases are used for convenience and do not imply that the disclosure associated with such phrases is necessary for the subject matter or that such disclosure applies to all configurations of the subject matter. The disclosure associated with such phrases may apply to all configurations or one or more configurations. One or more examples of the disclosure associated with such phrases may be provided. Phrases such as "aspect" or "some aspects" may refer to one or more aspects, and vice versa, and this similarly applies to other foregoing phrases.

[0101] The phrase “at least one of” following a series of items, along with the terms “and” or “or” used to separate any of these items, modifies the entire list, not each of its constituent items. The phrase “at least one of” does not require the selection of at least one item; rather, it allows for the inclusion of the meaning of: at least one of any of these items, and / or at least one of any combination of these items, and / or at least one of each of these items. As an example, each of the phrases “at least one of A, B, and C” or “at least one of A, B, or C” refers to only A, only B, or only C; any combination of A, B, and C; and / or at least one of each of A, B, and C.

[0102] It should be understood that the specific order or hierarchy of the disclosed steps, operations, or processes is an example of an exemplary method. Unless otherwise expressly stated, it should be understood that the specific order or hierarchy of steps, operations, or processes can be performed in a different order. Some steps, operations, or processes can be performed simultaneously. The appended method claims (if any) present elements of various steps, operations, or processes in a sample order and are not intended to limit one to the specific order or hierarchy presented. These can be performed serially, linearly, in parallel, or in different orders. It should be understood that the described instructions, operations, and systems can generally be integrated together in a single software / hardware product or packaged into multiple software / hardware products.

[0103] Terms such as top, bottom, front, back, side, horizontal, and vertical refer to arbitrary frames of reference, not ordinary gravitational frames of reference. Therefore, such terms can extend upward, downward, diagonally, or horizontally within a gravitational frame of reference.

[0104] This disclosure is provided to enable any person skilled in the art to practice the various aspects described herein. In some instances, well-known structures and components are shown in block diagram form to avoid confusion with the concepts of this subject matter. This disclosure provides various examples of this subject matter, and this subject matter is not limited to these examples. Various modifications to these aspects will be apparent to those skilled in the art, and the principles described herein can be applied to other aspects.

[0105] All structural and functional equivalents of the elements of the various aspects described throughout this disclosure are known or will later become apparent to a person skilled in the art, and such equivalents are expressly incorporated herein by reference and are intended to be covered in the claims. Furthermore, nothing disclosed herein is intended to serve the public, whether or not such disclosure is expressly stated in the claims. No claim element should be interpreted in accordance with 35 U.S.SC §112(f) unless the element is expressly stated using the phrase “component for…” or, in the case of a method claim, using the phrase “step for…”.

[0106] Those skilled in the art will understand that the various exemplary blocks, modules, elements, components, methods, and algorithms described herein can be implemented as hardware, electronic hardware, computer software, or combinations thereof. To illustrate this hardware-software interchangeability, various exemplary blocks, modules, elements, components, methods, and algorithms have been described above in terms of their functionality. Whether such functionality is implemented as hardware or software depends on the specific application and the design constraints imposed on the system as a whole. Those skilled in the art can implement the described functionality in different ways for each specific application. Various components and blocks can be arranged differently (e.g., in different orders or in different ways), all without departing from the scope of the subject matter.

[0107] The title, description of the drawings, abstract, and figures are hereby incorporated in this disclosure and are provided as illustrative examples rather than as limiting descriptions. It is understood at the time of filing this document that they are not intended to limit the scope or meaning of the claims. Furthermore, in the detailed description, it will be apparent that, for the purpose of simplifying this disclosure, the description provides illustrative examples, and various features are grouped together in various specific embodiments. The approach of this disclosure should not be construed as reflecting an intention to require more features than are expressly stated in each claim. Rather, as reflected in the claims, the subject matter of the invention does not lie in all features of a single disclosed configuration or operation. The claims are hereby incorporated in the detailed description, wherein each claim is independently claimed as a separate subject matter.

[0108] The claims are not intended to be limited to the aspects described herein, but should be given the full scope consistent with the language of the claims and to cover all legal equivalents. Nevertheless, none of the claims is intended to include subject matter that fails to meet the requirements of applicable patent law, nor should it be interpreted in this way.

Claims

1. A system comprising: an electronic control unit (ECU); and a battery monitoring circuit configured to: determine a broken conductor ratio value for each of a plurality of cells in a battery; determine that a first cell and a second cell of the plurality of cells have a potential broken conductor condition based on a comparison between the broken conductor ratio value for each of the first cell and the second cell and a predetermined threshold, wherein the broken conductor ratio value not exceeding the predetermined threshold indicates a potential broken conductor condition; determine whether the potential broken conductor condition associated with the second cell corresponds to a true broken conductor fault detection based on a comparison between the broken conductor ratio value for a third cell of the plurality of cells and the predetermined threshold; and send an indication to the ECU of which cell of the plurality of cells is associated with a true broken conductor fault detection to cause the battery to transition to a safe state.

2. The system of claim 1, wherein the battery monitoring circuit is further configured to determine that the second cell has a true broken conductor condition based on the broken conductor ratio value for the third cell not exceeding the predetermined threshold.

3. The system of claim 1, wherein the battery monitoring circuit is further configured to determine that the second cell does not have a true broken conductor condition based on the broken conductor ratio value for the third cell exceeding the predetermined threshold.

4. The system of claim 1, wherein the third cell is adjacent to the second cell and not adjacent to the first cell.

5. The system of claim 1, wherein the broken conductor ratio value is a ratio of a test voltage associated with a cell of the plurality of cells and a baseline voltage associated with the cell.

6. The system of claim 5, wherein the battery monitoring circuit is further configured to obtain a measurement of the test voltage based on a broken conductor detection switch being configured to be closed, and the battery monitoring circuit is further configured to obtain a measurement of the baseline voltage based on the broken conductor detection switch being configured to be open.

7. The system of claim 1, wherein the battery monitoring circuit is further configured to increment a counter associated with a cell of the plurality of cells in response to a determination that the cell has a true broken conductor condition.

8. The system of claim 7, wherein the battery monitoring circuit is further configured to determine a confirmation that the second cell has a true broken conductor condition after a plurality of iterations of comparing the broken conductor ratio value for each of the second cell and the third cell to the predetermined threshold. ​ 9. The system of claim 1, wherein the battery monitoring circuit is further configured to determine that the second battery cell has a true broken conductor condition based on the broken conductor ratio value of the second battery cell exceeding the predetermined threshold and the third battery cell not being adjacent to the second battery cell.

10. The system of claim 9, wherein a busbar is located between the second battery cell and the third battery cell.

11. The system of claim 1, wherein each of the plurality of battery cells are interconnected in series, and wherein the broken conductor ratio value of the third battery cell is determined sequentially after the broken conductor ratio value of the second battery cell is determined.

12. The system of claim 1, wherein the battery monitoring circuit is further configured to transition the battery between different safety state levels based on a number of battery cells in the plurality of battery cells determined to have a true broken conductor condition.

13. A method of managing a vehicle, the method comprising: determining a broken conductor ratio value for each of a plurality of battery cells in a battery; comparing the broken conductor ratio value of each of the plurality of battery cells to a predetermined threshold, wherein a first battery cell and a second battery cell of the plurality of battery cells have respective broken conductor ratio values that do not exceed the predetermined threshold; determining whether the second battery cell has a true broken conductor condition based on a comparison between the broken conductor ratio value of a third battery cell of the plurality of battery cells and the predetermined threshold; and sending an indication to an electronic control unit of the vehicle of whether one or more of the plurality of battery cells is associated with a broken conductor fault detection to cause the battery to transition to a safety state.

14. The method of claim 13, further comprising determining that the second battery cell has a true broken conductor condition based on the broken conductor ratio value of the third battery cell not exceeding the predetermined threshold.

15. The method of claim 13, further comprising determining that the second battery cell does not have a true broken conductor condition based on the broken conductor ratio value of the third battery cell exceeding the predetermined threshold.

16. The method of claim 13, further comprising: obtaining a measurement of a test voltage associated with a battery cell of the plurality of battery cells based on a broken conductor detection switch being configured to be closed; and obtaining a measurement of a baseline voltage associated with the battery cell based on the broken conductor detection switch being configured to be open.

17. The method of claim 13, further comprising incrementing a counter associated with a battery cell of the plurality of battery cells in response to a determination that the battery cell has a true broken conductor condition.

18. The method of claim 13, further comprising determining a confirmation that the second battery cell has a true open conductor condition after a plurality of iterations of comparing the open conductor ratio value of each of the second battery cell and the third battery cell to the predetermined threshold value.

19. The method of claim 13, further comprising determining that the second battery cell has a true open conductor condition based on the open conductor ratio value of the second battery cell exceeding the predetermined threshold value and the third battery cell not being adjacent to the second battery cell.

20. A vehicle, comprising: one or more sensors; an electronic control unit (ECU); and a battery monitoring circuit configured to: determine an open conductor ratio value for each of a plurality of battery cells in a battery; determine that a first battery cell and a second battery cell of the plurality of battery cells have a potential open conductor condition based on the open conductor ratio value of each of the first battery cell and the second battery cell not exceeding a predetermined threshold value; compare the open conductor ratio value of a third battery cell of the plurality of battery cells to the predetermined threshold value to determine whether the second battery cell has a true open conductor condition; and send an indication of an open conductor fault detection associated with one or more of the plurality of battery cells to the ECU to cause the battery to transition to a safe state. ​

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