DETECTION OF WIRE BREAKS IN BATTERY MODULES

Abstract

Methods, devices, or systems can be used to detect wire breaks in battery modules, such as those found in electric vehicles. These methods, devices, or systems may involve comparing voltage measurements from even and odd-numbered battery cells with pull-up resistors enabled and disabled. By using simultaneous measurements and determining comparisons between adjacent cells, the method can compensate for load fluctuations that might lead to false detections. The approach can be executed within a fault-tolerant time interval, allowing for the timely implementation of safety measures when a fault is detected.

Description

CROSS-REFERENCE TO RELATED REGISTRATION(S)

[0001] The present application claims the benefits of the preliminary US application No. 63 / 652,598 entitled “DETECTION OF OPEN WIRES IN BATTERY MODULES”, filed on May 28, 2024, the entire contents of which are hereby incorporated by reference. INTRODUCTION

[0002] This application relates to the detection of wire breaks and, in particular, to the detection of wire break faults associated with batteries. SUMMARY

[0003] The disclosed subject matter may include methods, systems, or devices for detecting wire breaks in battery modules, such as those found in electric vehicles. In one example, a method for detecting wire breaks may involve receiving voltage measurements from even and odd battery cells during the same time period, with the pull-up resistor enabled for one set of cells (even or odd) and disabled for the other. The method can then determine a relationship (e.g., a ratio) between these voltage measurements and compare it to a predefined threshold. If the ratio is within the threshold, an indication of a wire break can be sent. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Certain features of the technology in question are set forth in the accompanying claims. However, for illustrative purposes, several embodiments of the technology in question are shown in the following figures. Fig. Figure 1 illustrates an example block diagram of battery cells. Fig. Figure 2 illustrates an exemplary procedure in connection with baseline measurements for the detection of wire breakage. Fig. Figure 3A illustrates an example sequence diagram in connection with baseline measurements for the detection of wire breakage. Fig. Figure 3B illustrates an example sequence diagram related to baseline measurements for detecting wire breakage and can show the sequence of Fig. Continue with 3A. Fig.3C illustrates an example sequence diagram related to baseline measurements for detecting wire breakage and can show the sequence of Fig. Continue with 3B. Fig. Figure 4A illustrates an exemplary procedure for detecting wire break faults in connection with activated and inactivated pull-ups. Fig. Figure 4B illustrates an exemplary procedure for detecting wire breakage faults in connection with activated and deactivated pull-ups. Fig. Figure 5A illustrates an exemplary sequence diagram in connection with the measurement of the pull-up resistance activated on even cells for the detection of wire breakage faults. Fig. Figure 5B illustrates an exemplary sequence diagram related to the measurement of the pull-up resistor activated for the detection of wire breakage faults on odd-numbered cells, and can show the sequence of Fig.Continue with 5A. Fig. Figure 6 illustrates an example side view of a vehicle. DETAILED DESCRIPTION

[0005] The detailed description given below is intended as a description of various configurations of the technology in question and is not meant to represent the only configurations in which the technology in question can be practiced. The accompanying drawings are included herein and form part of the detailed description. The detailed description includes specific details for the purpose of providing a thorough understanding of the technology in question. However, it will be clear and obvious to those skilled in the art that the technology in question is not limited to the specific details set forth herein and can be practiced without them. In some cases, well-known structures and components are shown in the form of block diagrams to avoid obscuring the concepts of the technology in question.

[0006] Electric vehicles can contain large batteries capable of powering various high loads (drawing high currents) associated with components such as automotive electronics, motors, the powertrain, heat pumps, and heating, ventilation, and air conditioning (HVAC). If the load profile changes significantly within a short period while these loads are being powered, dips and spikes in the battery voltage will occur. If these dips and spikes are observed simultaneously while pull-up resistors are activated to detect wire breaks, this can lead to false positives (a dip higher than the threshold) and true negatives (the spike compensates for the exceptional dip when the pull-up resistor is activated).In safety-critical battery applications (at high Automotive Safety Integrity Level (ASIL)), wire break faults between battery cells should be diagnosed to the monitoring circuit within the fault-tolerant time interval (FTTI) to ensure a safe state. In one example, the disclosed subject matter provides methods, devices, or systems for determining wire break faults based on a comparison of the voltage measured for even-numbered cells when a pull-up resistor is activated with the voltage measured for odd-numbered cells when a pull-up resistor is not activated during the same time interval. This approach can reduce or eliminate the need to perform certain load profiles or baseline measurements.

[0007] Fig.Figure 1 illustrates an example block diagram of battery cells that may be found in an electric vehicle. The battery pack 100 can contain a variety of cells (e.g., 12, 16, 18, 24, or more cells in the pack 100). As shown, the pack 100 can include, among others, cell 101, cell 102, cell 103, or cell 104. The variety of battery cells can be connected in series within the pack 100 and can be monitored by one or more application-specific integrated circuits (ASICs), as further described herein.

[0008] ASICs can be used for voltage measurement in methods that may include a pull-up resistor to detect wire breaks. In one example implementation, a pull-up resistor can be connected between the cell voltage or the input line to the supply voltage, or a pull-down resistor can be connected to ground. Fluctuations in the battery cell voltage can then be measured, and these voltage fluctuations can be used to detect wire breaks. However, the reliability of wire break detection in certain methods is questionable if the load profile changes significantly (e.g., different combinations and intensities of loads while driving), which can lead to false positives.

[0009] Fig.Figure 2 illustrates an exemplary procedure 110 for detecting wire breaks, which can use comparisons with baseline measurements. Table 1 provides additional context for procedure 110. In block 120, baseline measurements (e.g., voltage measurements) are obtained during an initial time interval (t1) in which the pull-up resistors for cell 101 and cell 102 are disabled during t1. Therefore, in this example, a voltage can be measured at cell 101 with pull-up resistors (hereafter referred to as pull-ups) disabled, and a voltage can be measured at cell 102 with pull-ups disabled.

[0010] In block 140, measurements with pull-ups enabled can be obtained on even-numbered cells (e.g., cell 102 of pack 100, among others) in a second time interval (t2). In block 160, measurements with pull-ups enabled can be obtained on odd-numbered cells (e.g., cell 101 of pack 100, among others) in a third time interval (t3). Table 1 Steps category Measurements of cell no. 102 Measurements of cell no. 101 1 Baseline measurement (all pull-ups disabled) V 102.ADC.wo.PU V 101.ADC.wo.PU 2 Measurement with activated pull-up for even channels V 102.ADC.w.PU 3 Measurement with activated pull-up for odd channels V 101.ADC.w.PU 4 Criteria for detecting wire breakage defects - FALSE V102.ADC.wo.PUV102.ADC.w.PU<15% V101.ADC.wo.PUV101.ADC.w.PU<15% Criteria for detecting wire breakage defects - TRUE V102.ADC.wo.PUV102.ADC.w.PU≥15% V101.ADC.wo.PUV101.ADC.w.PU≥15%

[0011] In Block 180, the relationship (e.g., the ratio) between the baseline measurement of Block 120 - Cell 102 (without pull-ups) and the pull-up-enabled measurement of Block 140 - Cell 102 can be determined within a threshold. The threshold can be greater than or equal to 15% (other values ​​are conceivable, and this is only an example), and the threshold can be determined based on a load profile (as further described herein). As an example regarding threshold determination, it can be composed of a typical value and a tolerance. In this case, it can be a typical value of 10% + 5% tolerance. The typical value of 10% can be based on the value of the internal pull-up resistor and the input resistance of the analog-to-digital converter (ADC) within the ASIC. This value can vary between ASICs from different vendors.The 5% tolerance can be based on the load profile and component variations. As explained in more detail herein, setting the threshold based on the different types of loads that may operate in a system (e.g., vehicle 300) can be challenging. In block 182, based on compliance with the threshold for block 180, a wire break detection indication for cell 102 can be sent.

[0012] In Block 185, the relationship (e.g., the ratio) between the baseline measurement of Block 120 - Cell 101 (without pull-ups) and the pull-up-activated measurement of Block 160 - Cell 101 can be determined within a threshold value. The threshold value can be greater than or equal to 15% and can be determined based on a load profile (as further described herein). In Block 187, based on compliance with the threshold value for Block 185, a wire break detection indication for Cell 101 can be sent. Following a wire break indication, various actions can be taken, such as transmitting an audible, visual, or haptic alarm to the driver, determining whether the vehicle is in a safe operating state, and stopping the vehicle within a specified time frame.

[0013] Procedure 110 can produce false positive results if the electric vehicle's loads change significantly between measurement periods (e.g., between t1, t2, or t3). False positive results can lead to inefficient use of time and resources. For example, even if the vehicle is in a safe state, its use may be interrupted due to false positive alarms, thus impacting vehicle availability despite the absence of a fault.

[0014] Fig. 3A to Fig. 3C illustrate exemplary sequence diagrams for the subject of Fig. 2 (Procedure 110). As in Fig. As shown in Figure 3A, baseline measurement steps can be performed where the microcontroller unit (MCU) 20 communicates with one or more cell monitoring ASICs as shown. Fig.As shown in Figure 3B, wire break measurement steps (OW measurement steps) can be performed with pull-ups (PUs) on even cells. Fig. 3B communicates the MCU 20 with one or more cell monitoring ASICs, as shown, and the MCU 20 can determine ratios and check thresholds, as shown in Table 1. As shown in Fig. As shown in Figure 3C, OW measurement steps can be performed using pull-ups (PUs) on odd-numbered cells. Fig. 3C communicates the MCU 20 with one or more cell monitoring ASICs, as shown, and the MCU 20 can determine ratios and check thresholds, as shown in Table 1.

[0015] Fig.Figure 3A illustrates an example sequence diagram 340 related to baseline measurements for wire break detection. In step 341, the sequence starts with the microcontroller unit (MCU) 20, which initiates the baseline measurement process. In step 342, the MCU 20 sends a command to start the baseline measurement to the cell monitoring ASIC 21. In step 343, the MCU 20 sends a similar command to start the baseline measurement to the cell monitoring ASIC 22. In step 344, the MCU 20 sends the command to start the baseline measurement to the cell monitoring ASIC X, which represents all additional ASICs in the system. In step 345, after receiving these commands, the cell monitoring ASICs stop the cell balancing operations and begin measuring the cell voltages approximately simultaneously. In step 346, the system waits for a conversion time period (e.g. 100 ms) to enable precise voltage measurements.In step 347, after the conversion time, MCU 20 sends a command to read the ADC conversion result registers to cell monitoring ASIC 21. In step 348, MCU 20 sends a similar command to read the ADC conversion result registers to cell monitoring ASIC 22. In step 349, MCU 20 sends the command to read the ADC conversion result registers to cell monitoring ASIC X. In step 350, cell monitoring ASIC X responds by sending the ADC conversion results of its channels to MCU 20. In step 351, cell monitoring ASIC 22 sends its ADC conversion results of its channels to MCU 20. In step 352, cell monitoring ASIC 21 sends its ADC conversion results of its channels to MCU 20. In step 353, MCU 20 receives and processes the ADC conversion results from ASIC 21. In step 354, MCU 20 receives and processes the ADC conversion results from ASIC 22.In step 355, the MCU 20 receives and processes the ADC conversion results from other ASICs X for the baseline measurement process.

[0016] Fig.Figure 3B illustrates an example sequence diagram 360 related to measurements for detecting wire break faults with pull-ups enabled on even-numbered cells. In step 361, MCU 20 initiates the wire break measurement process (OW measurement process) on even-numbered cells. In step 362, MCU 20 sends a command to start the OW even measurement to cell monitoring ASIC 21. In step 363, MCU 20 sends a similar command to cell monitoring ASIC 22. In step 364, MCU 20 sends the command to start the OW even measurement to cell monitoring ASIC X. In step 365, after receiving these commands, the cell monitoring ASICs stop cell balancing and start the voltage measurement of the cells with pull-ups enabled on even-numbered cells approximately simultaneously. In step 366, the system waits for a conversion time period (e.g. 100 ms).In step 367, MCU 20 sends a command to read the ADC conversion result registers to cell monitoring ASIC 21. In step 368, MCU 20 sends a similar command to cell monitoring ASIC 22. In step 369, MCU 20 sends the command to read the ADC conversion result registers to cell monitoring ASIC X. In step 370, cell monitoring ASIC X sends its ADC conversion results to MCU 20. In step 371, cell monitoring ASIC 22 sends its ADC conversion results to MCU 20. In step 372, cell monitoring ASIC 21 sends its ADC conversion results to MCU 20. In step 373, MCU 20 receives and processes the ADC conversion results from ASIC 21. In step 374, MCU 20 receives and processes the ADC conversion results from ASIC 22. In step 375, MCU 20 receives and processes the ADC conversion results from other ASICs X.In step 376, the MCU determines 20 ratios and checks thresholds as shown in Table 1, step 4.

[0017] Fig.3C illustrates an exemplary sequence diagram 380 related to wire break detection measurements with pull-ups enabled on odd-numbered cells. In step 381, MCU 20 initiates the wire break measurement process (OW measurement process) on odd-numbered cells. In step 382, ​​MCU 20 sends a command to start the OW-odd measurement to cell monitoring ASIC 21. In step 383, MCU 20 sends a similar command to cell monitoring ASIC 22. In step 384, MCU 20 sends the command to start the OW-odd measurement to cell monitoring ASIC X. In step 385, upon receiving these commands, the cell monitoring ASICs stop cell balancing and start voltage measurement of the cells with pull-ups enabled on odd-numbered cells. In step 386, the system waits for a conversion time period (e.g., 100 ms). In step 387, the MCU 20 sends a command to read the ADC conversion result registers to the cell monitoring ASIC 21.In step 388, MCU 20 sends a similar instruction to cell monitoring ASIC 22. In step 389, MCU 20 sends the instruction to read the ADC conversion result registers to cell monitoring ASIC X. In step 390, cell monitoring ASIC X sends its ADC conversion results to MCU 20. In step 391, cell monitoring ASIC 22 sends its ADC conversion results to MCU 20. In step 392, cell monitoring ASIC 21 sends its ADC conversion results to MCU 20. In step 393, MCU 20 receives and processes the ADC conversion results from ASIC 21. In step 394, MCU 20 receives and processes the ADC conversion results from ASIC 22. In step 395, MCU 20 receives and processes the ADC conversion results from other ASICs X. In step 396, the MCU determines 20 ratios and checks thresholds as shown in Table 1, step 4.

[0018] Fig. 4A and Fig.Figure 4B illustrates the respective exemplary methods 205 and 245 for detecting wire breakage faults in conjunction with the respective activated and deactivated pull-ups. Table 2 provides additional context for the methods. With reference to Fig.In Block 210, measurements (e.g., voltage measurements) with activated pull-ups on even-numbered cells (e.g., cell 102 of pack 100, among others) can be obtained at or near the first time interval (t1). Additionally, measurements with deactivated pull-ups on odd-numbered cells (e.g., cell 101 of pack 100, among others) can be obtained at or near the first time interval (t1) (e.g., simultaneous measurements of cells in this step). Because the determination uses two parallel measurements (e.g., the same time window), it may be insensitive to load variations (dI / dt). In Block 230, the ratio of activated pull-up measurements on even-numbered cells (e.g., cell 102) to deactivated pull-up measurements on odd-numbered cells (e.g., cell 101) can be determined, provided it lies within a threshold value. The threshold can be less than or equal to 0.8 or greater than or equal to 1.2 (e.g., outside the limits of + / - 20% of 1).The threshold may have been determined based on consideration of one or more tolerances in the battery or circuit design. In block 240, based on compliance with the threshold for block 230, a wire break fault detection indication for cell 102 may be sent. Following a wire break fault indication, various actions may be taken, including sending an audible, visual, or haptic alarm to the driver, determining whether the vehicle is in a safe operating state, and stopping the vehicle within a specified timeframe.

[0019] With reference to Fig.In Block 250, measurements (e.g., voltage measurements) with activated pull-ups on odd-numbered cells (e.g., cell 101 of pack 100, etc.) can be obtained at or near a second time interval (t2). Additionally, measurements with deactivated pull-ups on even-numbered cells (e.g., cell 102 of pack 100, etc.) can be performed at or near the second time interval (t2) (e.g., by simultaneously performing measurements on cells in this step). Because the determination uses two parallel measurements (e.g., the same time window), it is insensitive to load fluctuations (dI / dt). In Block 260, the ratio between the activated pull-up measurement on odd-numbered cells (e.g., cell 101) and the deactivated pull-up measurement on even-numbered cells (e.g., cell 102) can be determined, provided it lies within a threshold value. The threshold can be less than or equal to 0.8 or greater than or equal to 1.2 (e.g., outside the limits of + / - 20% of 1).The threshold may have been determined based on consideration of one or more tolerances in the battery or circuit design. In Block 270, based on compliance with the threshold regarding Block 260, a wire break detection indication for cell 102 may be sent. A single measurement (e.g., Step 1 or Step 3 of Table 2) is sufficient to detect wire breaks, but it is considered herein that performing both procedures (e.g., Step 1 and Step 3) may provide a higher level of integrity. Table 2 Steps category Measurements of cell no. 102 Measurements of cell no. 101 1 Measurement with activated pull-up for even channels V 102.ADC.w.PU V 101.ADC.wo.PU 2 Criteria for detecting wire breakage faults - FALSE 0.8<V102.ADC.w.PUV102.ADC.wo.PU<1.2 Criteria for detecting wire breakage faults - TRUE 0.8≥V102.ADC.w.PUV101.ADC.wo.PU≥1.2 3 Measurement with activated pull-up for odd channels V 102.ADC.wo.PU V 101.ADC.w.PU 4 Criteria for detecting wire breakage faults - FALSE 0.8<V102.ADC.wo.PUV101.ADC.w.PU<1.2 Criteria for detecting wire breakage faults - TRUE 0.8≥V101.ADC.wo.PUV102.ADC.w.PU≥1.2

[0020] With further reference to Fig. 4A and Fig.In 4B, instead of a baseline measurement performed in a different time window (e.g., procedure 110), a pull-up resistor can be activated on the even-numbered cell and not activated on the odd-numbered cell (or vice versa). Additionally, even and odd measurements can be taken simultaneously, and a ratio is determined. Therefore, if significant load fluctuations occur, these fluctuations should be reflected in both measurements, and when a ratio is determined, all significant fluctuations should cancel each other out. It should be noted that the cells in these channels may have dedicated analog-to-digital converters (ADCs), and therefore no multiplexing occurs, and the battery cells are measured in the same time window.

[0021] Fig. 5A to Fig. 5B illustrates exemplary sequence diagrams for the subject of Fig. 4A or Fig.4B (e.g., Procedure 205 and Procedure 245). As in Fig. As shown in Figure 5A, wire break measurement steps (OW measurement steps) can be performed with pull-ups (PUs) on even cells. Fig. 5A allows the MCU 20 to communicate with one or more cell monitoring ASICs, as shown, and the MCU 20 can determine ratios and check thresholds, as shown in Table 2. As shown in Fig. As shown in Figure 5B, OW measurement steps can be performed using pull-ups (PUs) on odd-numbered cells. Fig. 5B communicates the MCU 20 with one or more cell monitoring ASICs, as shown, and the MCU 20 can determine ratios (e.g. relationships) and check thresholds, as shown in Table 2.

[0022] Fig.Figure 5A illustrates an example sequence diagram 500 related to the measurement of the pull-up resistor, which is enabled for detecting wire break faults on even-numbered cells. In step 501, the MCU 20 initiates the wire break measurement process (OW measurement process) on even-numbered cells. In step 502, the MCU 20 sends a command to start the OW even measurement to the cell monitoring ASIC 21. In step 503, the MCU 20 sends a similar command to the cell monitoring ASIC 22. In step 504, the MCU 20 sends the command to start the OW even measurement to the cell monitoring ASIC. In step 505, upon receiving these commands, the cell monitoring ASICs stop cell balancing, enable pull-ups on even-numbered cells, and start the voltage measurement of all cells. In step 506, the system waits for a conversion time period (e.g. 100 ms).In step 507, MCU 20 sends a command to read the ADC conversion result registers to cell monitoring ASIC 21. In step 508, MCU 20 sends a similar command to cell monitoring ASIC 22. In step 509, MCU 20 sends the command to read the ADC conversion result registers to cell monitoring ASIC X. In step 510, cell monitoring ASIC X sends its ADC conversion results to MCU 20. In step 511, cell monitoring ASIC 22 sends its ADC conversion results to MCU 20. In step 512, cell monitoring ASIC 21 sends its ADC conversion results to MCU 20. In step 513, MCU 20 receives and processes the ADC conversion results from ASIC 21. In step 514, MCU 20 receives and processes the ADC conversion results from ASIC 22. In step 515, MCU 20 receives and processes the ADC conversion results from other ASICs X.In step 516, the MCU calculates 20 ratios and checks threshold values, as shown in Table 2, step 2.

[0023] Fig.Figure 5B illustrates an example sequence diagram 520 related to the measurement of the pull-up resistor, which is enabled for detecting wire break faults on odd-numbered cells. In step 521, MCU 20 initiates the wire break measurement process (OW measurement process) on odd-numbered cells. In step 522, MCU 20 sends a command to start the OW-odd measurement to cell monitoring ASIC 21. In step 523, MCU 20 sends a similar command to cell monitoring ASIC 22. In step 524, MCU 20 sends the command to start the OW-odd measurement to the cell monitoring ASIC. In step 525, upon receiving these commands, the cell monitoring ASICs stop cell balancing, enable pull-ups on odd-numbered cells, and start the voltage measurement of all cells. In step 526, the system waits for a conversion time of 100 ms. In step 527, the MCU 20 sends a command to read the ADC conversion result registers to the cell monitoring ASIC 21.In step 528, MCU 20 sends a similar instruction to cell monitoring ASIC 22. In step 529, MCU 20 sends the instruction to read the ADC conversion result registers to cell monitoring ASIC X. In step 530, cell monitoring ASIC X sends its ADC conversion results to MCU 20. In step 531, cell monitoring ASIC 22 sends its ADC conversion results to MCU 20. In step 532, cell monitoring ASIC 21 sends its ADC conversion results to MCU 20. In step 533, MCU 20 receives and processes the ADC conversion results from ASIC 21. In step 534, MCU 20 receives and processes the ADC conversion results from ASIC 22. In step 535, MCU 20 receives and processes the ADC conversion results. from other ASICs X. In step 536, the MCU determines 20 ratios and checks thresholds, as shown in Table 2, step 4.

[0024] Fig.Figure 6 illustrates an exemplary side view of the vehicle 300. As shown, the vehicle 300 may include one or more battery packs, such as the high-voltage (HV) battery pack 310 (e.g., 450 V), which may be positioned near the central body section 335 of the vehicle 300. The HV battery pack 310 may be coupled to one or more electrical systems of the vehicle 300 to provide power to the electrical systems. As further described herein, ECU 10, ECU 15, or ECU 30 may be communicatively linked or have power distributed and may be functionally redundant for power or other operations of electronic components of the vehicle 300. It should be noted that one or more battery modules may constitute a battery pack for the vehicle 300.

[0025] In one or more implementations, the vehicle 300 can be an electric vehicle comprising one or more electric motors that drive the vehicle's wheels 302 using electrical power from the HV battery pack 310. Alternatively, in one or more implementations, the vehicle 300 can also include one or more chemically driven engines, such as a gas-powered engine or a fuel cell-powered engine. Electric vehicles can be, for example, fully electric or partially electric (e.g., hybrid or plug-in hybrid).In various implementations, the Vehicle 300 can be a fully autonomous vehicle capable of navigating lanes without a human operator or driver, a partially autonomous vehicle capable of navigating some lanes without a human operator or driver, or navigating lanes with the supervision of a human operator, an unmanned vehicle capable of navigating lanes or other routes without human occupants, or a human-operated (non-autonomous) vehicle configured for a human operator.

[0026] In the example of Fig.6. The vehicle 300 can be implemented as a flatbed truck (e.g., a pickup) with a battery pack 310. As shown, the HV battery pack 310 can include one or more battery modules 315, which can contain one or more battery cells 320 (e.g., cell 101 to cell 104). However, this is for illustrative purposes only, and in other implementations the HV battery pack 310 can be provided without battery modules 315 (e.g., in a cell-to-pack configuration, pack 100).

[0027] As in Fig.As shown in Figure 6, the vehicle 300 can include a support structure such as a chassis 325 (e.g., a frame, an inner frame, or another support structure). The chassis 325 can support various components of the vehicle 300. As shown, in some implementations, the chassis 325 can extend over a front section 330 (e.g., an engine or hood section), a mid-body section 335, and a rear section 336 (e.g., a trunk, payload, or luggage compartment section) of the vehicle 300. In one or more implementations, the HV battery pack 310 can be installed on the chassis 325 (e.g., in one or more of the front section 330, the mid-body section 335, or the rear section 336). As shown, the HV battery pack 310 can include one or more busbars (e.g., one or more current collector elements) or be electrically coupled to them. In the example of Fig. 6 The vehicle 300 includes a first busbar 337 and a second busbar 338, one or both of which may include electrically conductive material to connect or otherwise electrically couple the battery module(s) 315 or battery cell(s) 320 to other electrical components of the vehicle 300 in order to supply electrical power to various systems or components of the vehicle 300.

[0028] In other implementations, the vehicle 300 may be implemented as another type of electric flatbed truck, electric delivery van, electric automobile, electric vehicle, electric motorcycle, electric scooter, electric passenger car, electric passenger or cargo truck, hybrid vehicle or other vehicles such as sea or air transport vehicles, aircraft, helicopters, submarines, boats or drones and / or any other mobile installation with a battery pack 310 (which, for example, supplies power to the propulsion or drive components of the mobile installation).

[0029] A method, system, or device can be configured to receive, in a first time interval, a first voltage measurement of a second battery cell, wherein the second battery cell has an activated pull-up resistor and is an even cell; to receive, in a first time interval, a second voltage measurement of a first battery cell, wherein the first battery cell has a deactivated pull-up resistor and is an odd cell; and to determine that the first voltage measurement and the second voltage measurement have a first relationship (e.g.,Determine that the first voltage measurement and the second voltage measurement have a second relationship (e.g., ratio) within a first threshold; receive, in a first time interval, a first voltage measurement of a second battery cell, wherein the second battery cell has a disabled pull-up resistor and the second battery cell is an even cell; receive, in the first time interval, a second voltage measurement of a first battery cell, wherein the first battery cell has an enabled pull-up resistor and the first battery cell is an odd cell; determine that the first voltage measurement and the second voltage measurement have a second relationship (e.g., ratio) within a second threshold; and, based on determining that the first relationship (e.g., the ratio) is within the first threshold or the second relationship (e.g., the ratio) is within the second threshold, send an indication of wire break detection.Based on the indication of a wire break fault, the vehicle can send an alarm or automatically enter a safe mode (e.g., stopping the vehicle's driving functions, switching off one or more loads, or the like). After a wire break fault is indicated, various actions can be taken, such as sending an audible, visual, or haptic alarm to the driver, determining whether the vehicle is in a safe operating state, or stopping the vehicle within a specified timeframe. All combinations mentioned in this paragraph (including the omission or addition of steps) and the various procedures (e.g., ...) are described in this paragraph. Fig. 2 to Fig. 5B) are being considered.

[0030] A system, method, or device for detecting and responding to wire break faults in a battery pack can be provided. In one example, the system can include a plurality of battery cells arranged in series; one or more application-specific integrated circuits (ASICs) coupled to the battery cells, including a microcontroller unit. The microcontroller unit can be configured to obtain a first voltage measurement from an even-numbered battery cell of the plurality with the pull-up resistor enabled at a first time point; obtain a second voltage measurement from an odd-numbered battery cell of the plurality with the pull-up resistor disabled at the first time point; determine a relationship (e.g., a ratio) between the first voltage measurement and the second voltage measurement; and generate a wire break fault alarm if the relationship (e.g., a ratio) is exceeded.the ratio) exceeds a predetermined threshold. All combinations (including the removal or addition of steps) in this paragraph and the preceding paragraphs, such as the various procedures (e.g., . Fig. 2 to Fig. 5B) will be considered in a manner consistent with the other sections of the detailed description.

[0031] A method, system, or device for detecting and responding to wire break faults in a battery system can be provided. In an example, a method can include: receiving, at a first time interval, a first voltage measurement of a second battery cell, wherein the second battery cell has an activated pull-up resistor and is an even cell; receiving, at a first time interval, a second voltage measurement of a first battery cell, wherein the first battery cell has a deactivated pull-up resistor and is an odd cell; determining that the first voltage measurement and the second voltage measurement have a first relationship (e.g., ratio) within a first threshold; and transmitting a first indication of wire break fault detection based on the determination that the first relationship (e.g., ratio) is within the first threshold.The first and second battery cells can be measured using dedicated analog-to-digital converters. The procedure can further include transmitting instructions to bring a vehicle to a safe operating state based on the first indication of a wire break detection fault. Sending the first indication can include transmitting at least one audible, visual, or haptic alarm. The threshold can be in the range of 0.8 to 1.2. The first indication can be sent to a component of an electric vehicle's electronic control unit (ECU). The first and second battery cells can be part of an electric vehicle's battery pack. The first threshold can be determined based on a load profile of a battery system connected to the battery pack.The procedure may further include receiving, at a second time interval, a third voltage measurement of the second battery cell with the pull-up resistor disabled; receiving, at a second time interval, a fourth voltage measurement of the first battery cell with the pull-up resistor enabled; determining that a second relationship (e.g., ratio) between the third and fourth voltage measurements lies within a second threshold; and transmitting a second indication of wire break detection based on the determination that the second relationship (e.g., ratio) lies within the second threshold. Receiving the first or second voltage measurement may be based on the detection that the cell balancing operations have completed.All combinations (including the removal or addition of steps) in this paragraph are considered in a manner consistent with the other sections of the detailed description.

[0032] The methods, systems, or devices disclosed herein can be integrated into electric vehicles or other equipment. The circuit blocks disclosed herein can be distributed with or combined with one or more ECUs or other devices. The methods, systems, or devices disclosed herein can be integrated into products, such as various function-specific or zone-specific electronic control units (ECUs).

[0033] As used herein, the phrase "at least one of" before a list of elements with the expression "and" or "or" to separate any one of the elements modifies the list as a whole, rather than each element of the list (i.e., each element). The phrase "at least one of" does not require the selection of at least one of each of the listed elements; rather, the phrase allows for a meaning that includes at least one of any one of the elements and / or at least one of any combination of the elements and / or at least one of each of the elements. For example, the phrases "at least one of A, B, and C" or "at least one of A, B, or C" refer, respectively, 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.

[0034] When an element is described herein as "connected" or "coupled" to another element, it is understood that the elements may be directly connected to the other element or have intermediate elements that exist between the elements. Conversely, when an element is described as "directly connected" or "directly coupled" to another element, it is understood that no intermediate elements exist in the "direct" connection between the elements. However, the existence of a direct connection does not preclude other connections in which intermediate elements may exist.

[0035] The predicate words "configured to," "operational for," and "programmed to" do not imply any particular tangible or intangible modification of an object, but are instead used interchangeably. In one or more implementations, a processor configured to monitor and control an operation or component can also mean that the processor is programmed to monitor and control the operation, or that the processor is operational to monitor and control the operation. Likewise, a processor configured to execute code can be interpreted as a processor programmed to execute code or operational to execute code.

[0036] Terms such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the technology in question, the disclosure, the present disclosure, other variations thereof, and the like are used for simplification purposes and do not imply that a disclosure relating to such a term (or such terms) is essential to the technology in question, or that such disclosure applies to all configurations of the technology in question.A revelation referring to such a term (or terms) may apply to all configurations or to one or more configurations. A revelation referring to such a term (or terms) may provide one or more examples. A term, such as an aspect or some aspects, may refer to one or more aspects and vice versa, and this applies similarly to other foregoing terms.

[0037] The various techniques described herein can be implemented using hardware, firmware, software, or, where appropriate, combinations thereof. This hardware, firmware, and software may be located in facilities situated at various nodes of a communications network. The facilities may operate individually or in combination to perform the procedures described herein. Additionally, the word "or" is generally used unless otherwise provided herein. The procedures listed herein may be implemented locally, remotely, or in combinations of local and remote systems, and are configured to perform a function that can be implemented using software, hardware, or combinations thereof in the environments described above.

[0038] The word "exemplary" is used herein to mean "serving as an example, case, or illustration." Any embodiment described herein as "exemplary" or as an "example" is not necessarily to be construed as preferred or advantageous over other embodiments. Furthermore, to the extent that the expression "include," "feature," or the like is used in the description or the claims, such expression is to be included in a manner similar to the expression "comprise" as "comprise" is interpreted when used as a transitional word in a claim.

[0039] All structural and functional equivalents to the elements of the various aspects described herein that are known or will subsequently become known to persons skilled in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Furthermore, nothing disclosed herein is intended to be made available to the public, regardless of whether such disclosure is expressly mentioned in the claims. No claim element is to be understood within the meaning of 35 USC § 112(6) unless the element is expressly identified using the term "means for" or, in the case of a process claim, the element is identified using the term "step for".

[0040] The preceding description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications of these aspects will be readily apparent to those skilled in the art, and the generic principles defined herein can be applied to other aspects. Thus, the claims are not intended to be limited to the aspects shown herein but are intended to correspond to the full scope of protection consistent with the linguistic claims, where reference to a singular element is not intended to mean "one and only one" unless expressly stated otherwise, but rather "one or more". Unless expressly stated otherwise, the expression "some" refers to one or more. Masculine pronouns (e.g., *sein*) include the feminine and neuter genders (e.g., *ihr* and *sein*) and vice versa.Headings and subheadings, if any, are used for simplification only and do not limit the disclosure contained herein. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 652,598

[0001] Cited non-patent literature

[0000] Title “DETECTION OF OPEN WIRES IN BATTERY MODULES”, submitted on May 28, 2024

[0001]

Claims

[1] Procedure, encompassing: Receiving, in a first time period, a first voltage measurement of a second battery cell, wherein the second battery cell has an activated pull-up resistor and the second battery cell is a straight cell; Receiving, in the first time interval, a second voltage measurement of a first battery cell, wherein the first battery cell has the deactivated pull-up resistor and the first battery cell is an odd cell; Determine that the first voltage measurement and the second voltage measurement have a first ratio within a first threshold; and Sending an initial indication of a wire break fault detection based on the determination that the first relationship is within the first threshold. [2] Method according to claim 1, wherein the first battery cell and the second battery cell are measured using dedicated analog-to-digital converters. [3] Method according to claim 1, further comprising sending instructions to place a vehicle into a safe operating state based on the first indication of the detection of wire break faults, wherein the safe operating state comprises switching off one or more loads. [4] Method according to claim 1, wherein sending the first display comprises transmitting an audible alarm, a visual alarm or a haptic alarm. [5] Method according to claim 1, wherein the threshold comprises a range between 0.8 and 1.

2. [6] Method according to claim 1, wherein the first display is sent to a component of an electronic control unit (ECU) of an electric vehicle. [7] Method according to claim 1, wherein the first battery cell and the second battery cell are part of a battery pack of an electric vehicle. [8] Method according to claim 7, wherein the first threshold is determined on the basis of a load profile of a battery system connected to the battery pack. [9] The method of claim 1, further comprising: Received, in a second time period, a third voltage measurement of the second battery cell with the pull-up resistor deactivated; Received, in the second time period, a fourth voltage measurement of the first battery cell with the activated pull-up resistor; Determine that a second ratio of the third voltage measurement and the fourth voltage measurement lies within a second threshold; and Sending a second indication of wire break detection based on the determination that the second ratio is within the second threshold. [10] A facility that is configured to: Receiving, in a first time period, a first voltage measurement of a second battery cell, wherein the second battery cell has an activated pull-up resistor and the second battery cell is a straight cell; Receiving, in the first time interval, a second voltage measurement of a first battery cell, wherein the first battery cell has the deactivated pull-up resistor and the first battery cell is an odd cell; Determine that the first voltage measurement and the second voltage measurement have a first ratio within a first threshold; and Sending an initial indication of a wire break fault detection based on the determination that the first relationship is within the first threshold. [11] Device according to claim 10, wherein the first battery cell and the second battery cell are measured using dedicated analog-to-digital converters. [12] Device according to claim 10, further comprising the transmission of instructions to bring a vehicle into a safe operating state based on the first indication of the detection of wire break faults. [13] Device according to claim 10, wherein sending the first display comprises transmitting an audible alarm, a visual alarm or a haptic alarm. [14] Device according to claim 10, wherein the threshold comprises a range between 0.8 and 1.

2. [15] Device according to claim 10, wherein the first display is sent to a component of an electronic control unit (ECU) of an electric vehicle. [16] Device according to claim 10, wherein the first battery cell and the second battery cell are part of a battery pack of an electric vehicle. [17] Device according to claim 16, wherein the first threshold is determined on the basis of a load profile of a battery system connected to the battery pack. [18] Device according to claim 10, further comprising: Received, in a second time period, a third voltage measurement of the second battery cell with the pull-up resistor deactivated; Received, in the second time period, a fourth voltage measurement of the first battery cell with the activated pull-up resistor; Determine that a second ratio of the third voltage measurement and the fourth voltage measurement lies within a second threshold; and Sending a second indication of wire break detection based on the determination that the second ratio is within the second threshold. [19] Device according to claim 10, wherein the device comprises a microcontroller unit. [20] System for detecting wire break faults in a battery pack, comprising: a large number of battery cells arranged in a series; one or more application-specific integrated circuits (ASICs) coupled to the battery cells; and a microcontroller unit configured to: Obtaining an initial voltage measurement from a single battery cell of the multitude of battery cells with activated pull-up resistor in an initial time period; Obtaining a second voltage measurement from an odd-numbered battery cell of the multitude of battery cells with the pull-up resistor deactivated in the first time interval; Determining a ratio between the first voltage measurement and the second voltage measurement; and Generate a wire break alarm when the ratio exceeds a predetermined threshold.

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