Battery system and battery management method

Abstract

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

Description

Technical Field

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

Background Art

[0002] Electric or semi-electric vehicles, such as wheel loaders, excavators, trucks (e.g., dump trucks, transport trucks, articulated dump trucks, etc.), truck-type tractors (i.e., bulldozers), graders, continuous miners, feeder breakers, roof bolters, utility vehicles for mining, load-haul-dump (LHD) vehicles, underground mining loaders, underground articulated trucks, etc., include one or more batteries. The one or more batteries include various connections (i.e., electrical connections) to power one or more motors, heating and / or cooling systems, hydraulic systems, navigation systems, lighting systems, electronic devices, auxiliary systems, and the like. However, one or more of the connections can fail, for example, due to damage, improper connection, long-term use, etc., and connection failures can cause damage to one or more batteries and / or machines, and may require repair, replacement, or otherwise machine downtime.

[0003] U.S. Patent No. 10,720,626 (‘626 Patent), issued to Harris et al. on July 21, 2020, describes a system and method for positioning and managing battery cells within a battery pack for an electric vehicle. In particular, the ‘626 Patent discloses a battery management system and an interconnect assembly that communicates with the battery management system. Further, the ‘626 Patent discloses that the interconnect assembly includes one or more thermistors positioned proximate to the battery cells to sense the temperature of the battery cells. Additionally, the thermistors can be connected via a flexible printed circuit board to form a temperature sensing ribbon. However, the thermistors of the ‘626 Patent monitor the temperature of the battery cells, not the battery terminals or the bus bars. Further, the system of the ‘626 Patent does not monitor the temperature to detect potential failures of one or more connections and does not initiate one or more warnings or other preventive measures.

[0004] The systems, devices, and methods of the present disclosure can address or solve one or more of the above-described problems and / or other problems in the art. However, the scope of the present disclosure is defined by the appended claims and not by the ability to solve any particular problem. SUMMARY OF THE INVENTION

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

[0006] In one aspect, a battery system for a machine can include one or more battery module cell busbars, one or more terminal busbars, an interconnection system, and a battery module circuit. The one or more terminal busbars can include couplings configured to couple the battery system to one or more components of the machine. The interconnection system can couple one or more battery module cells to the one or more terminal busbars. The battery module circuit can be coupled to one or more portions of the interconnection system. The battery module circuit can include one or more thermistors positioned at least partially overlapping with the one or more terminal busbars.

[0007] In some additional aspects, a battery management method can include initiating a machine operation of a machine. The machine can include a battery system, a battery management system coupled to the battery system, a motor powered by the battery system, and a user interface coupled to the battery management system. The battery system can include a flexible circuit board including one or more battery module cell busbars, one or more terminal busbars, and one or more thermistors. The one or more thermistors can at least partially overlap with the one or more terminal busbars. The method can include monitoring the temperature of the one or more terminal busbars using the one or more thermistors, and initiating a first warning or action when the one or more thermistors detect a terminal busbar temperature exceeding a first threshold temperature. The first warning or action can include sending a signal to the user interface to indicate a high battery temperature warning.

[0008] In a further aspect, the machine may include one or more ground engaging elements, a battery system, a battery management system coupled to the battery system, a motor powered by the battery system and configured to drive the one or more ground engaging elements, and a user interface coupled to the battery management system. The battery system may include a flexible circuit board including one or more battery module cell busbars, one or more terminal busbars, and one or more thermistors. The one or more thermistors may at least partially overlap the one or more terminal busbars. When the one or more thermistors detect a terminal busbar temperature exceeding a threshold temperature, the battery management system may be configured to reduce the rated output of the motor or disconnect the battery system from the motor.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2A

Figure 2B

Figure 3

Figure 4

Mode for Carrying Out the Invention

[0010] The foregoing general description and the following detailed description are both merely illustrative and explanatory and do not limit the claimed features. As used herein, the terms "comprises", "comprising", "having", "including", or other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, in the present disclosure, relative terms such as, for example, "about", "substantially", "essentially", and "approximately" are used to indicate that the recited value may vary by ±10%.

[0011] FIG. 1 shows a perspective view of an exemplary vehicle or machine 10 that can be an electric vehicle or a machine. As discussed in detail below, the machine 10 includes a battery system 12 that includes one or more temperature sensors or thermistors (FIGS. 2A, 2B, and 3). The machine 10 may include a battery management system 14 that communicates with one or more aspects or portions of the battery system 12, for example. The machine 10 also includes a controller 102 that is coupled to or remote from the machine 10, for example. The machine 10 may include one or more user interfaces 16 that are positioned within an operating station 18, for example. The operating station 18 (e.g., a cab) may be positioned on the machine 10 at a central or forward portion of the machine frame 20, for example, or may be remote from the machine 10 (not shown). In these aspects, as shown in FIGS. 1 and 2A, one or more portions of each of the battery system 12, the battery management system 14, the controller 102, and / or the user interface 16 may communicate (e.g., via a wired or wireless connection) to form, for example, a control system 100. In these aspects, as discussed in detail below, when the temperature of one or more terminals or busbars of the battery system 12 exceeds one or more threshold temperatures, the battery management system 14, the controller 102, and / or the user interface 16 may initiate one or more warnings and / or one or more steps or preventive measures.

[0012] As shown in FIG. 1, the battery system 12 can be positioned at a rear portion of the machine 10. Alternatively, the battery system 12 may be positioned anywhere on the machine 10. Further, in some aspects, the battery system 12 may be removable, for example, to be easily exchanged with a charged battery system 12 that is charged away from the machine 10 to extend the operating time of the machine 10 and reduce charging downtime.

[0013] The battery system 12 can supply power to the motor 22 and / or other components of the machine 10. The machine 10 can include one or more ground engaging elements, such as wheels 24, that can be driven by the motor 22. In another aspect, the machine 10 can alternatively have a truck (not shown). In one aspect, the machine 10 can be fully electric-driven, for example, in a state where the machine 10 is fully powered by the battery system 12. Although not shown, the machine 10 can be semi-electric-driven (i.e., hybrid), and can include, for example, an engine that helps drive the wheels 24 and / or serves to power one or more additional components of the machine 10. Further, although not shown, the machine 10 can include one or more unit controllers (i.e., motor controllers, engine controllers, etc.) that can be incorporated into the controller 102 or can be separately but communicably connected to the controller 102.

[0014] Controller 102 may communicate with one or more features or parts of machine 10. Controller 102 may, for example, start one or more displays or warnings on user interface 16, lower the rated output of one or more components of machine 10, and / or stop or shut off one or more components of machine 10 or machine 10 as a whole, and may receive inputs and send outputs to operate machine 10. Although not shown, controller 102 may be coupled to or may include one or more memory units that may include instructions for controller 102 to start one or more displays or one or more preventive steps or procedures. Controller 102 may be a separate controller on machine 10 or may be incorporated into a central vehicle controller (e.g., a main power or operation controller, etc.). Alternatively, controller 102 may be integrated into one or more of battery management system 12, a motor control module, or another dedicated control module on machine 10. In one aspect, machine 10 may be a electro-hydraulic wheel loader, and controller 102 may control one or more electrical switches or valves to control one or more hydraulic cylinders or electrical elements to operate machine 10.

[0015] The controller 102 may embody a single microprocessor or multiple microprocessors that may include a system for performing any of the operations referred to herein. For example, the controller 102 may include a processor such as a memory, a secondary storage device, and a central processing unit or any other system for accomplishing tasks consistent with the present disclosure. The memory or secondary storage device associated with the controller 102 may be a non-transitory computer-readable medium that stores data and / or software routines that may assist the controller 102 in performing its functions, such as the method or process 400 functions of FIG. 4, as described below. Further, the memory or secondary storage device associated with the controller 102 may also store data received from various inputs or sensors associated with the machine 10. A number of commercially available microprocessors may be configured to perform the functions of the controller 102. Of course, the controller 102 may readily embody a general machine controller that can control a number of other machine functions. Various other known circuits, including signal conditioning circuits, communication circuits, hydraulic or other actuation circuits, and other suitable circuits, may be associated with the controller 102. As discussed herein, the controller 102 may receive various inputs (e.g., from various sensors), and based on the various inputs, the controller 102 may signal one or more displays or warnings (e.g., on the user interface 16) and / or initiate one or more preventive steps or procedures.

[0016] Furthermore, the machine 10 may include one or more implements 26 (e.g., buckets) coupled to and movable relative to the machine frame 20. As shown, the machine 10 can be a wheel loader having a bucket as the implement 26. The bucket can be coupled to the machine frame 20 and movable relative to the machine frame 20 via one or more hydraulic systems 28 that include a set of one or more rods and cylinders that can be operated by the movement and / or pressurization of hydraulic fluid via one or more pumps. Additionally, the machine 10 may include, be coupled to, and / or communicate with one or more navigation systems 30 (e.g., a global positioning system, a total station system, a LIDAR system, a string line sensor system, one or more proximity sensors, etc.). The machine 10 may also include one or more lighting systems 32, e.g., including one or more lights. As will be discussed in more detail below, various aspects of the machine 10 can be powered by the battery system 12.

[0017] The machine 10 is shown as a wheel loader including a bucket as the implement 26, but the present disclosure is not so limited. For example, the machine 10 can be a shovel having a bucket, a truck having a movable truck bed, a tractor having a blade, a ripper, a grader having a circle and a leveling blade, or any other vehicle or machine with or without a movable or positionable implement. Additionally, in some embodiments, the machine 10 can be for boats or marine applications. In other aspects, the machine 10 can be an energy storage machine, e.g., a stationary energy storage device, or for other energy storage applications. In these aspects, the battery system 12 and / or the motor 22 can help propel the machine or vehicle and can also help control the movement and / or position of the respective implement or other aspects of the machine 10, based on the driver's control. In other aspects, the battery system 12 can help power one or more other aspects of a machine, device, or application.

[0018] Figures 2A and 2B illustrate additional features of the battery system 12. As described above, the battery system 12 can be coupled to and power one or more aspects of the machine 10. The battery system 12 can include a battery module 40 that includes, for example, a plurality of battery packs or module cells coupled (i.e., welded) to a plurality of module cell busbars 42. Although not shown, a corresponding number of battery packs or module cells are positioned adjacent to each of the module cell busbars 42 (below or in the middle of the page of FIG. 2A). The plurality of module cell busbars 42 can be coupled and / or supported together by a frame 44. As shown, in one aspect, the battery module 40 can include 12 module cell busbars 42. Nevertheless, the battery module 40 can include fewer or more module cells and module cell busbars 42, and it should be noted that the module cells and module cell busbars 42 can be arranged in parallel or in a mirror arrangement (as shown) or in any other arrangement. Further, the module cells and module cell busbars 42 can be substantially identical, or one or more of the module cells and module cell busbars 42 can be of different sizes, power, etc. Further, the battery system 12 can include, for example, one or more crossover busbars 42A as part of the battery module 40. The crossover busbar 42A can help control the operation of the battery module 40 that includes the module cell busbars 42. For example, the crossover busbar 42A can help electrically connect two or more module cell busbars 42. In some aspects, the crossover busbar 42A can help connect a plurality of module cell busbars 42 in series.

[0019] The battery module 40 also includes, or is coupled to, an interconnection system 46 that includes one or more terminal busbars 48. The interconnection system 46 can connect each of the module cell busbars 42 to one or more terminal busbars 48. The interconnection system 46 can also connect the crossover busbar 42A to other components of the battery module 40. For example, the interconnection system 46 may include two interconnection rails 50A, 50B and may include a plurality of arms 52. The battery module 40 can include two terminal busbars 48, with each of the interconnection rails 50A, 50B connecting the module cell busbar 42 to one of the two terminal busbars 48. The arms 52 can extend from the interconnection rails 50A, 50B, for example, substantially perpendicular thereto, to connect the interconnection rails 50A, 50B to their respective module cell busbars 42. Further, the interconnection rails 50A, 50B may also be positioned adjacent to or proximate to one or more module cell busbars 42, in which case one or more extensions 54 can extend from the interconnection rails 50A, 50B, for example, substantially perpendicular thereto, to connect the interconnection rails 50A, 50B to their respective battery modules 40. The extension 54 in FIG. 2A may be shorter than the arm 52. Alternatively, in some aspects, the extension 54 may be the same or similar in length to the arm 52 and can extend, for example, directly below or beneath each respective module cell busbar 42. In these aspects, the arms 52 and / or the extensions 54 can be coupled to their respective module cell busbars 42 via coupling elements 56 that include, for example, one or more welds, solders, bolts, or other suitable connections.

[0020] As shown, the battery module 40 may include two terminal busbars 48, and the terminal busbars 48 (along with the interconnect system 46) may be configured to route power from and / or to one or more module cell busbars 42. For example, each terminal busbar 48 may include one or more couplings, ports, or openings 58 configured to receive connection elements and thus route power to or from one or more module cell busbars 42. The interconnect system 46 may include one or more busbar arms 60 for coupling (i.e., electrically connecting) the interconnect rails 50A, 50B to the terminal busbars 48, for example via one or more additional coupling elements 56. Further, the interconnect system 46 may include one or more other coupling elements 56 positioned on or adjacent to, for example, the arms 52 and / or extensions 54 to electrically couple each battery module 40 to the interconnect system 46 and thus to the terminal busbars 48. Further, the interconnect system 46 may include one or more terminals 62 for electrically connecting the battery module 40 to one or more components of the machine 10, for example, to the battery management system 14. The various components or parts of the interconnect system 46, including the terminal busbars 48, interconnect rails 50A, 50B, arms 52, extensions 54, coupling elements 56, busbar arms 60, terminals 62, etc., may be formed of a metallic material (e.g., aluminum).

[0021] Furthermore, the battery module 40 includes a battery module circuit 64, which includes, for example, a printed circuit board system 66 or a flexible circuit board system 66 (FIG. 3). As shown in FIG. 2A, the battery module circuit 64 can include, for example, a plurality of voltmeters 68 positioned on or adjacent to each module cell bus bar 42. The voltmeters 68 can serve to measure and / or detect the power flowing from each module cell and / or the power remaining in each module cell via each battery module cell bus bar 42. The voltmeters 68 can be positioned on the battery module circuit 64 such that each voltmeter 68 is positioned on a respective arm 52 or, alternatively, on a portion of each respective interconnect rail 50A, 50B adjacent to a respective extension 54.

[0022] Further, as shown in detail in FIGS. 2B and 3, one or more thermistors 70 may be positioned on or adjacent to one or more portions of the battery module 40, for example, via a flexible circuit board system 66. For example, as shown in FIGS. 2A and 2B, the thermistor 70 may be coupled to the battery module circuit 64, for example, with the battery module circuit 64 on or including the flexible circuit board system 66 (FIG. 3). The thermistor 70 may be positioned on or adjacent to one or more terminal bus bars 48, for example, proximate to an opening 58 in the one or more terminal bus bars 48. In one aspect, one thermistor 70 is positioned on or adjacent to each of the terminal bus bars 48. As another alternative, one thermistor 70 may be positioned on or adjacent to one terminal bus bar 48. In these examples, the thermistor 70 may be positioned on a portion of the flexible circuit board system 66 such that the thermistor 70 may be positioned on a portion of the bus bar arm 60 that overlaps a portion of the terminal bus bar 48. For example, the thermistor 70 may be positioned at about 50% along the length of the bus bar arm 60, about 60% of the length of the bus bar arm 60, about 70% of the length of the bus bar arm 60, about 80% of the length of the bus bar arm 60, about 90% of the length of the bus bar arm 60, and so on. Further, as described above, each thermistor 70 is part of the flexible circuit board system 66. For example, each thermistor 70 may include one or more connection wires 72 that may be incorporated into respective portions of the flexible circuit board system 66.

[0023] As described above and as shown in FIG. 2A, the battery management system 14 can be coupled to the battery system 12, for example, via one or more connections of the battery module circuit 64 and / or via one or more connections of the flexible circuit board 66. For example, the battery management system 14 can be coupled to one or more of the terminals 62. As will be discussed in more detail below, the battery management system 14 can initiate one or more warnings and / or one or more preventive steps or procedures based on one or more signals received from the battery module circuit 64. For example, the battery management system 14 can receive from the thermistor 70 a signal indicative of the temperature on or adjacent to one or more of the terminal bus bars 48. In this manner, an increase in the temperature on or adjacent to one or more of the terminal bus bars 48 can indicate one or more potential problems or faults (i.e., connection faults, improper connections, etc.) or other potentially dangerous conditions. For example, if the thermistor 70 signals a temperature that exceeds a certain temperature, the battery management system 14 can initiate one or more warnings and / or preventions. In these manners, the battery management system 14 can signal different warnings and / or preventive measures to be taken depending on the temperature measured by the thermistor 70. For example, if the thermistor 70 detects a first temperature, the battery management system 14 can send a signal to the user interface 16 to indicate a high battery temperature warning. Next, if the thermistor 70 detects a second temperature that is higher than the first temperature, the battery management system 14 can send a signal to the motor 22 or the engine (not shown) to reduce the rated output. Further, if the thermistor 70 detects a third temperature that is higher than the second temperature, the battery management system 14 can send a signal to the motor 22, the engine, other components of the machine 10, or the entire machine 10 to shut down and stop the operation.As another or additional alternative, if the thermistor 70 detects one or more temperatures (i.e., one or more of a first temperature, a second temperature, a third temperature, or different temperatures), the battery management system 14 may, for example, in addition to or instead of reducing the rated output of the motor 22, disconnect one or more portions of the battery system 12 (i.e., the battery modules 40) from one or more other portions of the machine 10 (i.e., the motor 22).

[0024] FIG. 3 shows, for example, an aspect of the flexible circuit board system 66 separate from other aspects of the battery system 12, separated from the module cell bus bar 42, the frame 44, and the interconnect system 46 (FIG. 2A). The flexible circuit board system 66 may include two flexible circuit boards 66A, 66B, which may be connectable to respective portions of the battery system 12. For example, the flexible circuit boards 66A, 66B may be substantially mirror images of each other. Each flexible circuit board 66A, 66B may include longitudinal portions 74A, 74B, for example, to at least partially overlap the interconnect rails 50A, 50B of the interconnect system 46 (FIG. 2A). The longitudinal portions 74A, 74B may include one or more curved portions 74A, 74B that connect the longitudinal portions 76A, 76B to the terminal portions 78A, 78B, for example. Further, one or more reinforcements 80A, 80B may be coupled to one or more portions of the flexible circuit boards 66A, 66B to assist, for example, in coupling the flexible circuit boards 66A, 66B to the terminal portions 78A, 78B. As described above, the terminal portions 78A, 78B may at least partially overlap the terminals 62 for connecting the flexible circuit boards 66A, 66B to the battery management system 14 (FIG. 2A).

[0025] Furthermore, the flexible circuit boards 66A and 66B may each include a plurality of circuit arms, for example, a first circuit arm 82 and a plurality of second circuit arms 84 coupled to respective arms 52 and / or extensions 54 of the interconnect rails. For example, the circuit arm 82 may include one or more thermistors 70. The circuit arm 82 may at least partially overlap with the terminal bus bar 48 such that the thermistor 70 can monitor the temperature of the terminal bus bar 48, as described above. Further, the circuit arms 84 may be positioned on or adjacent to each module cell bus bar 42 and / or crossover bus bar 42A, for example, and may include one or more voltmeters 68 that measure and / or detect the electricity flowing from each module cell bus bar 42 and / or crossover bus bar 42A and / or the power remaining in each module cell bus bar 42 and / or crossover bus bar 42A. In one aspect, the flexible circuit board 66A may include one first circuit arm 82 and six second circuit arms 84. Further, in one aspect, the flexible circuit board 66B may include one first circuit arm 82 and seven second circuit arms 84. For both flexible circuit boards 66A and 66B, the second circuit arms 84 may extend from alternating sides of the longitudinal portions 74A, 74B.

[0026] Note that the number and / or arrangement of the circuit arms 82, 84 on each of the flexible circuit boards 66A, 66B may vary depending on, for example, the number and / or arrangement of the module cell bus bars 42, terminal bus bar 48, interconnect rails 50A, 50B arms 52, extensions 54, and / or other portions of the battery system 12. In these aspects, the first circuit arm 82 may be positioned at least partially overlapping with the terminal bus bar 48 to measure and / or detect the temperature of the terminal bus bar 48, for example, and the second circuit arms 84 may be positioned adjacent to or in proximity to the module cell bus bar 42 and / or crossover bus bar 42A, as described above.

[0027] FIG. 4 is a flow diagram depicting an exemplary method 400 that can be implemented by control system 100 (e.g., by one or more of battery management system 14, user interface 16, and / or controller 104) to automatically monitor and / or control one or more aspects or parts of machine 10. For example, when machine 10 is in an operating mode, control system 100 can monitor the temperature of one or more terminal busbars 48. Further, control system 100 may issue one or more warnings, or initiate one or more preventive procedures or actions, if the temperature exceeds one or more threshold temperatures. The one or more warnings and / or preventive procedures or actions can include indicating an improper or potentially defective connection to one or more terminal busbars 48, reducing the rated output of one or more components of machine 10, or shutting down or stopping one or more components of machine 10.

[0028] Method 400 includes an initial step 402 that includes initiating machine operation. For example, step 402 can include turning on the power to machine 10 or otherwise starting and operating machine 10. Operating machine 10 can include powering motor 22, operating appliance 26, and / or activating one or more of hydraulic system 28, navigation system 30, lighting system 32, control system 100, or other aspects of machine 10. Step 402 can include an operating action, e.g., starting machine 10 and / or instructing machine 10 to perform an operation (e.g., an earthmoving operation).

[0029] Next, method 400 includes step 404 of monitoring the temperature of one or more terminal busbars 48 having one or more thermistors 70. As described above, the thermistors 70 can be positioned on the flexible circuit board 66 and be part of the battery module circuit 64. Further, the thermistors 70 are positioned on or adjacent to each of the terminal busbars 48, for example, proximate to the openings 58 on the terminal busbars 48. As described below, an increase in the temperature of the terminal busbars 48 can indicate one or more potential problems or faults (i.e., connection faults) or other potentially dangerous conditions.

[0030] Method 400 also includes one or more of steps 406, 408, or 410. For example, when the thermistor 70 detects a first temperature (e.g., a first threshold temperature), step 406 includes initiating a first action or warning. For example, the first action or warning can include a signal user interface 16 indicating a high battery temperature warning, including, for example, a blinking light or icon, a buzzer, or other sound.

[0031] When the thermistor 70 detects a second temperature (e.g., a second threshold temperature higher than the first threshold temperature), step 408 includes initiating a second action or warning. In some aspects, the second action or warning can also include the first action or warning. The second action or warning can include signaling one or more other components of the motor 22, engine (not shown), or machine 10 to reduce the operating power or the rated output of the capacity or otherwise.

[0032] When the thermistor 70 detects a third temperature (e.g., a third threshold temperature higher than the second threshold temperature), step 410 includes initiating a third action or warning. In some aspects, the third action or warning may also include one or more of the first action or warning, or the second action or warning. The third action or warning may include signaling the motor 22, the engine (not shown), other components of the machine 10, or the entire machine 10 to shut down and stop operations.

[0033] Although not shown, method 400 may also include one or more other actions or warnings. For example, method 400 may include initiating the display of a warning on an additional user interface, e.g., within a control station or on a user interface remote from the machine 10. Alternatively or additionally, method 400 may include modifying the operating parameters of one or more other components or systems of the machine 10, e.g., raising the implement 26 that is disengaged from the ground, temporarily stopping or shutting down one or more of the hydraulic system 28, the navigation system 30, the lighting system 32, or other systems or components of the machine 10.

Industrial Applicability

[0034] A machine 10 and a control system 100 including a battery system 12, a battery management system 14, a user interface 16, and a controller 102 can help monitor the connection to one or more terminal bus bars 48. For example, one or more thermistors 70 may be positioned on or near the terminal bus bar 48. One or more thermistors 70 may be positioned proximate to one or more openings 58. For example, the terminal bus bar 48 is electrically coupled to one or more connection elements to route power to and / or from one or more module cell bus bars 42 and / or crossover bus bars 42A (e.g., via an interconnect system 46). Thus, the thermistor 70 can help monitor the temperature of the terminal bus bar 48. Further, the control system 100 including the battery system 12, the battery management system 14, the user interface 16, and the controller 102 can help initiate one or more warnings or preventive procedures or actions. One or more warnings or preventive procedures or actions can help warn the operator and / or prevent damage to other components of the machine 10 that may be caused by a malfunction or damage of the battery system 12 and / or the battery connection.

[0035] As described above, terminal 62 can be communicatively coupled to battery management system 14. In this manner, control system 100, which includes battery system 12, battery management system 14, user interface 16, and controller 102, monitors the temperature of terminal bus bar 48 and can initiate one or more warnings or preventive measures in response to the detected temperature, for example, because an increase in the temperature of terminal bus bar 48 can indicate an improper connection or potential connection failure. The one or more warnings or preventive measures can depend on the detected temperature. For example, if one thermistor 70 detects a terminal bus bar temperature that exceeds a first threshold temperature, control system 100 can send a signal to user interface 16 to indicate a high battery temperature warning, including, for example, a blinking light or icon, a buzzer, or other sound. If one thermistor 70 detects a terminal bus bar temperature that exceeds a second threshold temperature, control system 100 can send a signal to one or more other components of motor 22, an engine (not shown), or machine 10 and can reduce the operating power or rated output of the capacity or otherwise decrease it. Further, if one thermistor 70 detects a terminal bus bar temperature that exceeds a third threshold temperature, control system 100 can send a signal to motor 22, an engine (not shown), other components of machine 10, or the entire machine 10 to shut down and stop the operation. In these manners, control system 100 can help warn the operator of improper connections and / or potential connection failures and / or can help prevent overheating and / or damage to terminal bus bar 48 and / or other components of battery system 12 or machine 10.

[0036] Furthermore, as described above, the thermistor 70 may be included on the flexible circuit board 66. In this embodiment, the thermistor 70 may be positioned on or near one or more of the terminal bus bars 48 when the flexible circuit board 66 is positioned on various portions of the interconnect system 46. One or more thermistors 70 may be coupled to connection wires 72 that may be included on the flexible circuit board 66. In this embodiment, the connection wires 72 may be part of the battery module circuit 64 and may thus be connected to the terminals 62. Further, the voltmeter 68 may help monitor the power remaining in one or more of the battery modules 40. Although not shown, the battery module 40 may include, for example, one or more additional temperature sensors positioned on or adjacent to one or more of the module cell bus bars 42, crossover bus bars 42A, portions of the flexible circuit board 66, and / or other portions of the battery module 40 to assist in detecting the temperature of the module cell bus bars 42, crossover bus bars 42A, and / or one or more portions of the flexible circuit board 66. For example, one or more aspects of the battery system 12, battery management system 14, user interface 16, controller 102, or control system 100 may monitor the temperature of multiple portions of the battery module 40 and may detect a temperature difference between one or more portions of the battery module 40. For example, one or more portions of the control system 100 may initiate one or more warnings or preventive measures in response to the detected temperature difference. As another or additional method, if the thermistor 70 detects one or more temperatures (i.e., a first temperature, a second temperature, a third temperature, or one or more of different temperatures), the battery management system 14 may disconnect one or more portions of the battery system 12 (i.e., the battery module 40) from one or more other portions of the machine 10 (i.e., the motor 22), in addition to or instead of, for example, reducing the rated output of the motor 22.

[0037] In these aspects, the first temperature threshold may correspond to a first temperature difference threshold, e.g., about 5°C, between the temperature at one terminal bus bar 48 and the temperature at another location of the battery module 40 (e.g., one or more of the battery module cell bus bars 42). Similarly, the second temperature threshold may correspond to a second temperature difference threshold, e.g., about 10°C, between the temperature at one terminal bus bar 48 and the temperature at another location of the battery module 40 (e.g., one or more of the battery module cell bus bars 42). Finally, the third temperature threshold may correspond to a third temperature difference threshold, e.g., about 15°C, between the temperature at one terminal bus bar 48 and the temperature at another location of the battery module 40 (e.g., one or more of the battery module cell bus bars 42).

[0038] It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed systems, devices, and methods for a battery system without departing from the scope of the disclosure. Considering this specification and the accompanying drawings, other embodiments of the systems, devices, and methods for a battery system will become apparent to those skilled in the art. The specifications described herein, particularly the described examples, should be considered illustrative only, and the true scope of the disclosure is indicated by the following claims and their equivalents.

Claims

1. A battery system (12) for a machine (10), comprising: one or more battery module cell busbars (42); one or more terminal busbars (48) including a coupling (58) configured to couple the battery system (12) to one or more components of the machine (10); an interconnection system (46) coupling the one or more battery module cell busbars (42) to the one or more terminal busbars (48); a battery module circuit (64) coupled to one or more portions of the interconnection system (46), the battery module circuit (64) including one or more thermistors (70) positioned at least partially overlapping the one or more terminal busbars (48).

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

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

4. The battery system (12) of claim 3, further comprising a motor (22), wherein when the one or more thermistors (70) measure a temperature exceeding a second threshold temperature higher than the first threshold temperature, the battery management system (14) sends a signal to reduce the rated output of the motor (22).

5. The battery system (12) of claim 4, wherein when the one or more thermistors (70) measure a temperature exceeding a third threshold temperature higher than the second threshold temperature, the battery management system (14) sends a signal to stop the motor (22).

6. The one or more terminal busbars (48) include first and second terminal busbars (48), the one or more thermistors (70) include first and second terminal thermistors (70), the first thermistor (70) is positioned at least partially overlapping the first terminal busbar (48), and the second thermistor (70) is positioned at least partially overlapping the second terminal busbar (48), the battery system (12) according to any one of claims 1 to 5.

7. The first and second thermistors (70) are positioned on flexible printed circuit boards (66A, 66B), and the flexible printed circuit boards (66A, 66B) further include one or more voltmeters (68) for detecting power delivered by the one or more battery module cell busbars (42), the battery system (12) according to claim 6.

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

9. A battery management method (400), starting a mechanical operation of a machine (10), wherein the machine (10) is a battery system (12), the battery system (12) including a flexible circuit board (66A, 66B) including one or more battery module cell busbars (42), one or more terminal busbars (48), and one or more thermistors (70), the one or more thermistors (70) at least partially overlapping the one or more terminal busbars (48), a battery system (12); a battery management system (14) coupled to the battery system (12); a motor (22) powered by the battery system (12); Starting to include a user interface (16) coupled to the battery management system (14). Using the one or more thermistors (70) to monitor the temperature of the one or more terminal busbars (48). When the one or more thermistors (70) detect a terminal busbar temperature exceeding a first threshold temperature, starting a first warning or action, the first warning or action including transmitting a signal to the user interface (16) to indicate a high battery temperature warning. A battery management method (400) comprising starting.

10. When the one or more thermistors (70) detect a terminal busbar temperature exceeding a second threshold temperature higher than the first threshold temperature, starting a second warning or action, the second warning or action including reducing the rated output of the motor (22). The method (400) according to claim 9, further comprising starting.

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