Architecture for Battery Packs

Abstract

The battery assembly includes a housing and a plurality of battery modules within the housing, each battery module including an array of battery cells, one or more first sensors configured to measure one or more first parameters of a corresponding battery module, and a first processor configured to receive sensed signals from the one or more first sensors of the corresponding battery module. One or more second sensors are within the housing but external to the battery modules and configured to measure one or more second parameters of the battery assembly. A second processor within the housing is for receiving data from each of the first processors and the one or more second sensors and for sending controller input data to a controller external to the battery assembly, the controller input data being based on the data received from the first processor and the one or more second sensors.

Description

[Technical Field]

[0001]

[0001] The present disclosure relates generally to battery technology, and more particularly to architectures for battery assemblies. [Background technology]

[0002] Batteries are a common source of electrical power, for example, supplying direct current (DC) to a load. A battery has a positive terminal, or cathode, and a negative terminal, or anode. Multiple batteries can be combined in series and / or parallel to form a high-voltage and / or high-power DC power source.

[0003]

[0003] Rechargeable batteries can be charged and discharged, and such charge and discharge cycles can occur many times over the battery's life. For example, when a battery is discharged during use, it can be recharged using an applied current, during which the original composition of the battery electrodes can be fully or at least partially restored by a reverse current. Examples of such rechargeable batteries include lead-acid batteries and lithium-ion batteries. Batteries can be used in any number of applications, such as in consumer electronics devices, wearable devices, computers, electric and non-electric vehicles, and / or many other devices or systems that use DC power. [Brief explanation of the drawings]

[0004] [Figure 1]

[0004] Figure 1 illustrates a battery assembly according to one embodiment of the present disclosure, comprising a plurality of battery modules, each comprising a corresponding plurality of battery cells extending laterally between two corresponding cooling plates, wherein the battery assembly is within a housing. [Figure 2]

[0005] FIG. 2 illustrates a system including the battery assembly of FIG. 1, where the battery assembly supplies power to a load, according to one embodiment of the present disclosure. [Figure 3]

[0006] FIG. 3 illustrates a system at least partially similar to the system of FIG. 2, where the system of FIG. 3 includes multiple battery assemblies that power corresponding loads, according to one embodiment of the present disclosure. [Figure 4]

[0007] FIG. 4 illustrates a flow chart illustrating a method for operating the battery assembly of FIGS. 1-3 and the battery system of FIGS. 2 and 3 according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0005]

[0008] The drawings depict various embodiments of the present disclosure for purposes of illustration only and are not necessarily drawn to scale. Numerous variations, configurations and other embodiments will become apparent from the following detailed description.

[0006]

[0009] A battery system and related techniques are described. In one example, the system includes a battery assembly within a housing. The battery assembly includes a plurality of battery modules, where each battery module includes (i) an array of battery cells, (ii) one or more module-level sensors configured to measure one or more module-level parameters of the corresponding battery module, and (iii) a module-level processor configured to receive sensed signals from the one or more module-level sensors of the corresponding battery module. The battery assembly further includes an assembly-level processor (e.g., external to the individual battery modules and contained within the battery assembly housing) and one or more assembly-level sensors within the housing configured to measure one or more assembly-level parameters of the battery assembly. The assembly-level processor, in turn, can provide data to a controller configured to disconnect the battery assembly from a load in response to fault detection.

[0007]

[0010] Note that "module-level" components are included in each battery module of a battery assembly. In contrast, "assembly-level" components are external to the battery modules and may be common to one or more (e.g., all) of the battery modules. Examples of module-level sensors include voltage and temperature sensors within individual battery modules. Examples of assembly-level sensors include outgassing sensors and pressure relief sensors.

[0008]

[0011] In one example, the module-level processor processes the sensed signals from the corresponding module-level sensors and transmits information associated with the sensed signals to the assembly-level processor using one or more digital signals and one or more discrete signals, where transmitting the digital signals and the discrete signals improves the reliability of data communication between the module-level processor and the assembly-level processor.

[0009]

[0012] Numerous variations and embodiments will become apparent in light of this disclosure.

[0010] [General Overview]

[0013] Described herein are techniques for forming a battery system including a battery assembly, where the battery system includes redundancy for the operation of the battery system. In some examples, sensor data is redundantly communicated using digital and discrete signals. By way of example only, if the sensor data is from a temperature sensor, the digital signal may provide the sensed temperature value, a temperature profile over time, a rate of rise of the temperature, a location where the temperature was sensed, and / or other relevant information related to the sensed temperature. In contrast, the discrete signal indicates whether the sensed temperature represents an over-temperature fault condition. For example, the discrete signal has two states, such as a “no fault detected” state corresponding to a first voltage level of the discrete signal and a “fault detected” state corresponding to a second voltage level of the discrete signal. In one example, control signals (e.g., for controlling switches or contactors of a battery system) may also be communicated using digital and discrete signals, where such discrete signals have a first state corresponding to a “switch closed” mode of the switch and a second state corresponding to a “switch open” mode of the switch. In one example, the digital signals are transmitted over a corresponding digital bus, such as a Controller Area Network (CAN) bus, and in one example, the discrete signals are transmitted over a corresponding discrete bus, which may be an analog or discrete bus of any suitable type configured to transmit discrete signals.

[0011]

[0014] In some examples, a battery assembly includes a housing and multiple battery modules within the housing. In some such examples, each battery module includes (i) a corresponding array of battery cells, (ii) one or more corresponding module-level sensors configured to measure one or more corresponding module-level parameters of the corresponding battery module, and (iii) a corresponding module-level processor configured to receive sensed signals from the one or more corresponding module-level sensors of the corresponding battery module. Note that "module-level" components are included in each battery module of the battery assembly. In contrast, "assembly-level" components are included in the battery assembly but are external to the battery modules, e.g., are common to one or more (e.g., all) of the battery modules.

[0012]

[0015] In some examples, each battery module includes one or more cold plates, and in some such examples, each battery module includes two corresponding cold plates, with the battery cells of the corresponding battery module extending from near a first cold plate to near a second cold plate of the battery module.

[0013]

[0016] In one example, within a battery module, a corresponding module-level processor processes sensing signals from a corresponding module-level sensor. Examples of module-level sensors include voltage sensors and temperature sensors within an individual battery module. For example, the module-level processor receives temperature sensing signals and voltage sensing signals from the corresponding temperature and voltage sensors, respectively, and generates digital signals indicative of the sensed temperature and voltage. In one embodiment, the module-level processor also generates discrete signals indicative of whether the corresponding battery module has an over-temperature condition, an over-voltage condition, and / or an under-voltage condition. Thus, the sensory data from the sensors is used by the module-level processor to generate corresponding digital signals and corresponding discrete signals.

[0014]

[0017] In some examples, the battery assembly further includes an assembly-level processor and one or more assembly-level sensors. The assembly-level processor and assembly-level sensors may be common to all battery modules and may not be included in any of the battery modules. Examples of assembly-level sensors include a gas release sensor and a pressure relief sensor, as described below.

[0015]

[0018] In one embodiment, the assembly-level processor receives digital and discrete signals from multiple module-level processors, where the digital and discrete signals represent sensor data from various module-level sensors. Further, in one example, the assembly-level processor also generates additional digital and discrete signals for the sensed signals received from the assembly-level sensors.

[0016]

[0019] In some examples, the battery system includes a controller external to the battery assembly. The controller receives various digital and discrete signals from an assembly-level processor, where the digital and discrete signals represent sensory signals from various sensors (such as module-level sensors and assembly-level sensors) in the battery assembly. Receiving sensory data via the digital and discrete signals improves redundancy of data communication between the assembly-level processor and the controller.

[0017]

[0020] In one embodiment, the battery assembly is coupled to the load, for example, through one or more switches. In one example, the switches are contactors. In one example, the controller controls the switches (e.g., using digital and / or discrete control signals) based on digital and discrete signals received by the controller from an assembly-level processor. For example, in response to digital and discrete signals indicating a fault condition in the battery assembly, the controller opens at least one of the switches between the battery assembly and the load. In one example, the controller issues digital and discrete control signals to corresponding switches, for example, to improve communication redundancy between the controller and the switches, as described below.

[0018]

[0021] According to some embodiments of the present disclosure, these various approaches may be used individually or together to operate a battery system with increased redundancy.

[0019]

[0022] As used herein, the term "about" indicates that the recited value may be varied slightly or otherwise within acceptable tolerances, provided that the variation does not result in process or device incompatibility. For example, for some elements, the term "about" may refer to a variation of ±0.1%, while for other elements, the term "about" may refer to a variation of ±1% or ±10%, or any point therein. Also, as used herein, terms defined in the singular are intended to include terms defined in the plural, and vice versa.

[0020]

[0023] Reference herein to any range of values ​​expressly includes each value (including fractions and integers) subsumed within that range. For example, reference herein to the range "at least 50" or "at least about 50" includes integers such as 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, etc., and fractions such as 50.1, 50.2, 50.3, 50.4, 50.5, 50.6, 50.7, 50.8, 50.9, etc. By way of further example, references herein to the range "less than 50" or "less than about 50" include integers such as 49, 48, 47, 46, 45, 44, 43, 42, 41, 40, etc., and fractions such as 49.9, 49.8, 49.7, 49.6, 49.5, 49.4, 49.3, 49.2, 49.1, 49.0, etc.

[0021]

[0024] As used herein, the terms "substantially" or "substantial" are equally applicable when used in the negative sense to refer to the complete or nearly complete absence of a feature, characteristic, property, state, structure, item, or result. For example, a surface that is "substantially" flat is either completely flat or so nearly flat that the effect would be the same as if the surface were completely flat.

[0022] [Architecture - Battery Assembly]

[0025] FIG. 1 illustrates a battery assembly 100 according to one embodiment of the present disclosure, comprising a plurality of battery modules 104a, ..., 104N, each comprising a corresponding plurality of battery cells 132a, ..., 132P extending laterally between two corresponding cooling plates 130a and 130b, wherein the battery assembly 100 is within a housing 102.

[0023]

[0026] Thus, battery assembly 100 (also referred to herein as assembly 100) includes N battery modules 104a, ..., 104N, where N is a suitable positive integer. For example, there may be 8 modules or 16 modules (e.g., N=8 or 16), although N may have another suitable value. An example architecture for two example battery modules 104a and 104N is illustrated in FIG. 1 , and one or more (e.g., all) of the other battery modules may have a similar architecture. Example battery module 104a is described below, and such description applies to the other battery modules as well, unless otherwise noted.

[0024]

[0027] The battery module 104a includes one or more cold plates (e.g., including one or more metals and / or alloys thereof), such as cold plates 130a and 130b. Although not illustrated, one or more coolant pipes extend adjacent to (or through) the cold plates to keep the cold plates relatively cool (e.g., cooler than the battery cells) and facilitate the transfer of heat from the battery cells to the surroundings. In one example, the cold plates 130a and / or 130b of the various battery modules may form at least sections of an outer wall of the housing 102.

[0025]

[0028] In one example, the battery cells 132a,...,132P extend from near one cold plate 130a to near another cold plate 130b, although other layouts of the battery cells relative to the cold plates may be possible. Thus, in one example, there are P battery cells in each battery module 104, where P is a suitable integer. In another example, each battery module may have an unequal or different number of battery cells. In one example, there may be tens or hundreds of battery cells per battery module 104. Thus, for example, P may be in the range of 10 to 500, although other suitable values ​​of P may be possible.

[0026]

[0029] In one embodiment, the individual battery cells 132 may comprise any suitable type of battery cell. For example, the individual battery cells 132 may comprise lithium-ion battery cells, although the battery cells 132 may be of another suitable type, such as lead-acid battery cells or hydrogen cells. In one example, the multiple battery cells 132a,...,132P of the battery module 104 may be coupled in series and / or parallel connections.

[0027]

[0030] In one example, the battery cells 132a,...,132P may be of any suitable size and may have any suitable shape or form factor. In one embodiment, each battery cell 132 includes an electrolyte in a corresponding container, although the electrolyte and containers of the battery cells 132 are not illustrated in FIG.

[0028]

[0031] In one embodiment, each battery module 104 includes one or more temperature sensors 134 and / or one or more voltage sensors 135. For example, FIG. 1 illustrates battery modules 104a and 104N each including a temperature sensor 134 and a voltage sensor 135. In one example, the sensors within individual battery modules 104 are referred to herein as “module-level sensors” because each of these sensors measures parameters of the corresponding battery module 104 in which the sensor resides. For example, the temperature sensor 134 and voltage sensor 135 within module 104a specifically measure the temperature and output voltage of the battery cells of module 104a, the temperature sensor 134 and voltage sensor 135 within module 104N specifically measure the temperature and output voltage of the battery cells of module 104N, and so on.

[0029]

[0032] In one embodiment, the temperature sensor 134 of the module 104 outputs a sense signal 119a indicative of the sensed temperature. In one embodiment, the voltage sensor 135 of the module 104 outputs a sense signal 119b indicative of the sensed voltage.

[0030]

[0033] In one example, each battery module 104 includes a corresponding module-level processor 136. For example, Figure 1 illustrates each of modules 104a and 104N including a corresponding processor 136. The module processor 136 receives sensed signals from a corresponding temperature sensor 134 and a corresponding voltage sensor 135 of the corresponding module.

[0031]

[0034] The battery assembly 100 further includes a processor 116 that is common to each of the modules 104a,...,104N. Accordingly, the processor 116 is also referred to as an assembly-level processor. In one embodiment, the processor 116 receives sensor data from the individual module-level processors 136 of each of the modules 104a,...,104N.

[0032]

[0035] Battery assembly 100 includes one or more sensors, such as sensors 108a and 108b. Sensors 108a and 108b are common to each of modules 104a,...,104N and are therefore also referred to as assembly-level sensors. In one example, sensor 108a is a gas release sensor and sensor 108b is a pressure relief sensor, as described below.

[0033]

[0036] In one example, sensor 108a is an outgassing sensor. In one example, battery cell outgassing (also sometimes referred to as off-gassing) can occur during the early stages of battery failure. When battery cell outgassing occurs, if no action is taken to remedy the cause of the failure, the battery cell may progress to thermal runaway or even suddenly catch fire. In one example, outgassing can result from vaporization of the battery cell electrolyte and / or other gas(es) generated within the battery cell, for example, due to a fault condition within the battery cell. In such an example, such vapors and / or gases can be released from the battery cell. Examples of gases released from battery cells, such as lithium-ion battery cells, include hydrogen, methane, ethane, methylene, propylene, carbon monoxide, carbon dioxide, and / or organic carbonates. In one example, the gases released from the battery cell can depend on the electrolyte and / or other materials used within the battery cell and the type of battery cell (e.g., lithium-ion battery cell or another suitable type of battery cell).

[0034]

[0037] In one embodiment, the gas outflow sensor 108a is configured to detect a gas outflow event in one or more of the battery cells 132a,...,132P of the various modules 104a,...,104N. For example, the gas outflow sensor 108a is mounted proximate to a battery cell 132 of the battery module 104, and the gas outflow sensor 108a monitors the gas space inside the enclosure 102. The gas(es) monitored by the gas outflow sensor 108a may be based on the type of battery cell 132 used in the assembly 100. For example, if the battery cell 132 comprises a lithium-ion battery cell, the gas outflow sensor 108a may monitor lithium-ion battery electrolyte vapor and / or other gases potentially generated by such battery cell during a fault condition. The gas outflow sensor 108a may detect gas from the battery cell 132, for example, at a detection threshold at the parts per million (ppm) level.

[0035]

[0038] In one embodiment, the outgassing sensor 108a outputs a sensing signal 117a, which may be a discrete sensing signal, as described below. When the outgassing sensor 108a detects a gas leak (e.g., a gassing event) of at least a threshold amount (e.g., a threshold ppm level) from one or more battery cells 132, the sensing signal 117a indicates such detection. For example, upon detecting a gassing event, the sensing signal 117a changes from a first signal level to a second signal level.

[0036]

[0039] For example, when no outgassing event is detected (e.g., the detected outgassing is zero or at least less than a threshold outgassing level), outgassing sensor 108a may output sensing signal 117a at a first voltage (e.g., 0.50 V DC (direct current)). Upon detecting an outgassing event (e.g., the detected outgassing is equal to or greater than a threshold outgassing level), outgassing sensor 108a may output sensing signal 117a at a second voltage level (e.g., 3.0 V DC). Thus, sensing signal 117a provides an indication of the outgassing event.

[0037]

[0040] An outgassing event may be a warning or fault condition for the battery assembly 100. For example, in response to detecting an outgassing event, operation of the battery assembly 100 may be shut down, as described below.

[0038]

[0041] In one embodiment, during an outgassing event, gas pressure within the enclosure 102 increases due to, for example, evaporation of electrolyte in one or more of the battery cells 132 due to a fault condition in one or more battery cells. In one example, the outgassing sensor 108a detects such an outgassing event and indicates such detection through the sense signal 117a. As described below, preventative action may be taken (e.g., by the processor 116 and other controllers external to the battery assembly 100) to remedy the conditions causing the outgassing event (e.g., by shutting down the battery cells). However, in one example, the outgassing detection and / or such remedial actions may not be sufficient or timely, and the gas pressure within the enclosure 102 may increase. Such an increase in gas pressure may cause thermal runaway, a fire hazard, and / or structural damage to the enclosure 102.

[0039]

[0042] Thus, in one embodiment, the battery assembly includes a pressure relief device 109, where sensor 108b is a pressure relief sensor configured to sense a pressure relief event caused by the pressure relief device 109. For example, the pressure relief device 109 in the housing 102 releases gas pressure from the housing 102, for example, in response to the gas pressure in the housing 102 exceeding a threshold pressure value. In one example, the pressure relief device 109 is a burst or rupture disk attached to a wall of the housing 102. The burst or rupture disk is a pressure relief safety device that protects the assembly 100 from over-pressurization and the resulting fire hazard and / or structural damage. The pressure relief device may be any pressure relief device known in the art, including, by way of non-limiting example, a safety valve, a relief valve, a pressure relief valve, and a safety relief valve. For example, the pressure relief device 109 has a non-reclosing, sacrificial part that is a one-time use membrane or diaphragm. The diaphragm fails or ruptures above a predetermined pressure differential between the interior of the housing 102 and the ambient. For example, if the gas pressure inside the housing 102 exceeds a threshold pressure, the diaphragm fails or ruptures (referred to herein as a pressure relief event), thereby rapidly releasing gas from within the housing 102, thereby relieving or reducing the gas pressure within the housing 102. For example, once activated or ruptured, the pressure relief device 109 reduces the pressure within the housing 102 within a relatively short amount of time (e.g., within a few seconds or milliseconds or microseconds). In one example, once the diaphragm ruptures, it may not reseal, and the pressure relief device 109 may become inoperable until the diaphragm is repaired or replaced.

[0040]

[0043] In one embodiment, pressure relief sensor 108b senses a pressure relief event caused by pressure relief device 109. For example, pressure relief sensor 108b outputs sensing signal 117b indicative of the pressure relief event. In one example, sensing signal 117b may be a discrete sensing signal, as described below. In one example, pressure relief sensor 108b may be integrated with pressure relief device 109. For example, rupture of a diaphragm of pressure relief device 109 may be detected by pressure relief sensor 108b.

[0041]

[0044] For example, when no pressure relief event is detected, pressure relief sensor 108b may output sensing signal 117b at a first voltage. Upon detecting a pressure relief event, pressure relief sensor 108b may output sensing signal 117b at a second voltage level. Thus, sensing signal 117b provides an indication of the pressure relief event.

[0042]

[0045] A pressure relief event may be a warning or fault condition for the battery assembly 100. For example, in response to detecting a pressure relief event, operation of the battery assembly 100 may be shut down, as described below.

[0043]

[0046] Note that in one example, sensing signals 117a, 117b are discrete sensing signals, and discrete signals 117a, 117b are illustrated using dotted lines in FIG. 1 . For example, each of sensing signals 117a, 117b has two states. For example, a low value of sensing signal 117a implies that no outgassing event (e.g., any warning or fault condition) has been detected, and a high value of sensing signal 117a implies that a outgassing event (e.g., any warning or fault condition) has been detected. Similarly, a low value of sensing signal 117b implies that no pressure relief event (e.g., any warning or fault condition) has been detected, and a high value of sensing signal 117b implies that a pressure relief event (e.g., any warning or fault condition) has been detected.

[0044]

[0047] As described above, the sensing signals 117a, 117b are discrete signals. In contrast, in one example, the temperature sensing signal 119a detected by the temperature sensor 134 of each module 104 and / or the voltage sensing signal 119b detected by the voltage sensor 135 of each module 104 are analog signals. For example, the voltage value of the temperature sensing signal 119a represents the sensed temperature, and the voltage value of the voltage sensing signal 119b represents the sensed voltage.

[0045]

[0048] As described above, within a module 104 (such as module 104a), a corresponding processor 136 receives the analog temperature sensing signal 119a and the analog voltage sensing signal 119b. For each module 104, the corresponding processor 136 generates and transmits one or more digital signals 105 and one or more discrete signals 106 to the processor 116. For example, the processor 104a of module 104a transmits one or more digital signals 105a and one or more discrete signals 106a to the processor 116, the processor 104b of module 104b transmits one or more digital signals 105b and one or more discrete signals 106b to the processor 116, the processor 104N of module 104N transmits one or more digital signals 105N and one or more discrete signals 106N to the processor 116, and so on. In FIG. 1, the discrete signals 106a, 106b, ..., 106N are illustrated using dotted lines.

[0046]

[0049] For example, in example module 104a, the corresponding processor 136 receives an analog temperature sensing signal 119a from the temperature sensor 134, indicating the temperature of the module 104a. The processor 136 compares the sensed temperature to a threshold temperature to determine whether an over-temperature (or under-temperature) condition exists within the module 104a. In one example, the discrete signal 106a may indicate whether an over-temperature (or under-temperature) event has occurred. Thus, for example, a high level of the discrete signal 106a may indicate the occurrence of an over-temperature event, and a low level of the discrete signal 106a may indicate that an over-temperature event has not been detected.

[0047]

[0050] In another example, in example module 104a, a corresponding processor 136 receives a voltage sense signal 119b from a voltage sensor 135 indicating the voltage of the module 104a. The processor 136 compares the sensed voltage to a high threshold voltage to determine whether an over-voltage condition has occurred in a battery cell 132 of the module 104a. Similarly, the processor 136 compares the sensed voltage to a low threshold voltage to determine whether an under-voltage condition has occurred in a battery cell 132 of the module 104a.

[0048]

[0051] In one example, the discrete signal 106a may be a combination of multiple discrete signals. For example, a first one of the discrete signals 106a may represent whether an over-temperature event has occurred within the module 104a. Similarly, a second one of the discrete signals 106a may represent whether an over-voltage event has occurred within the module 104a. Similarly, a third one of the discrete signals 106a may represent whether an under-voltage event has occurred within the module 104a. Similarly, a fourth one of the discrete signals 106a may represent whether an under-temperature event has occurred within the module 104a.

[0049]

[0052] In one embodiment, the processor 136 of the module 104a may also send one or more digital signals 105a containing information associated with the sensed signals 119a, 119b to the processor 116. In one example, the digital signals 105a, 105b, ..., 105N are transmitted over a corresponding digital bus, such as a Controller Area Network (CAN) bus, although any other suitable digital communication protocol may be used.

[0050]

[0053] For example, the processor 136 of module 104a processes the corresponding sensed signals 119a, 119b to generate the digital signal 105a (similarly, the processor 136 of module 104b processes the corresponding sensed signals 119a, 119b to generate the digital signal 105b, and so on.) For example, suitable software running within the processor 136 processes the corresponding sensed signals 119a, 119b of the modules to generate the digital signal 105a.

[0051]

[0054] Digital signal 105a may include information regarding the temperature and / or voltage sensed by sensors 134, 135 of module 104a, digital signal 105b may include information regarding the temperature and / or voltage sensed by sensors 134, 135 of module 104b, etc. For example, digital signal 105a may include the actual detected temperature and / or voltage, a temperature and / or voltage profile over time, a rate of rise of the temperature and / or voltage, and / or other relevant information regarding the sensed temperature and / or voltage.

[0052]

[0055] In another example, temperature sensor 134 may measure temperatures at multiple locations within module 104a (e.g., may include more than one underlying temperature sensor). If any of these temperatures exceed the aforementioned threshold temperature, discrete signal 106a may transition to a warning / fault state, but may not identify which of the multiple locations the temperature exceeded the threshold temperature and / or may not identify the actual temperature. In contrast, digital signal 105a may identify the temperature at each of such multiple locations.

[0053]

[0056] Similarly, in one example, for voltage sense signal 119b, digital signal 105a may include the actual detected voltage and / or other relevant information regarding the sensed voltage. For example, voltage sensor 135 may measure the voltages of multiple groups of battery cells in module 104a. In one example, if any of these voltages fall below (or above) a low threshold voltage (or exceed a high threshold high voltage), discrete under-voltage (or over-voltage) sense signal 106a may transition to a warning / fault state, but may not identify which group of cells has an under-voltage (or over-voltage) condition or the actual value of the voltage. In contrast, digital signal 105a, in one example, may identify the actual voltage of each such group of battery cells.

[0054]

[0057] Thus, the processor 136 of each of these modules 104 communicates with the assembly-level processor 116 via a digital communication bus (e.g., digital signal 105a) and via a discrete signal communication bus (e.g., discrete signal 105b). Thus, the assembly-level processor 116 receives sensor data from the module-level processor 136 via two independent and distinct communication paths. This improves the reliability of communication between the processors 136 and 116. For example, if the processor 136 of module 104a is unable to generate the digital signal 105a from the sensed signals 119a, 119b, the processor 136 of module 104a may still be able to transmit the discrete signal 106a. Thus, in one example, communicating sensor data via two independent and distinct communication paths from the processor 136 to the processor 116 improves the reliability and redundancy of sensor data communication.

[0055] [Example system]

[0058] 2 illustrates a system 200 including the battery assembly 100 of FIG. 1 , where the battery assembly 100 supplies power to a load 224, according to one embodiment of the disclosure. The system 200 includes a controller 204 external to the battery assembly 100, where the controller 204 is in communication with the processor 116 of the assembly 100.

[0056]

[0059] For example, the processor 116 communicates with the controller 204 via a discrete communication bus 207a that communicates discrete signals 206a and also via a digital communication bus 207b that communicates digital signals 206b. In one example, the digital communication bus 207b is a CAN bus.

[0057]

[0060] Discrete communication bus 207a is illustrated as being a bidirectional communication bus. However, in another example, bidirectional communication bus 207a may be replaced by two unidirectional discrete communication buses (e.g., signals only travel in one direction), one for transmitting discrete signals from processor 116 to controller 204 and the other for transmitting discrete signals from controller 204 to processor 116.

[0058]

[0061] In one embodiment, processor 116 transmits discrete signals over discrete communication bus 207a, where the discrete signals indicate whether one or more warning or fault events have occurred (such as an over-temperature event, an over- or under-voltage event, a gas release event, a pressure relief event, and / or another suitable type of fault event). For example, a high value of the discrete signal may indicate the occurrence of a fault event, and a low value of the discrete signal may indicate that the fault event has not been sensed by the corresponding sensor.

[0059]

[0062] In one embodiment, digital signals 206b communicated over communication bus 207b provide digital information regarding various parameters sensed by various sensors of the battery module, e.g., as described with respect to digital signals 105a,..., 105N. For example, digital signals 206b may include temperature readings, voltage readings, ppm levels of outgassing detected by outgassing sensor 108a, pressure sensed by pressure relief sensor 108b, and / or other suitable information associated with the outputs of various sensors of assembly 100.

[0060]

[0063] In one example, processor 116 retransmits digital signals 105a...105N or transmits a summarized or combined version of digital signals 105a...105N as digital signal 206b to controller 204 via communication bus 207b. In one example, processor 116 retransmits discrete signals 106a...106N or transmits a summarized or combined version of discrete signals 106a...106N as discrete signal 206a to controller 204 via communication bus 207a. For example, instead of retransmitting individual discrete signals 106a...106N, processor 116 may transmit a single discrete signal 206a representing discrete signals 106a...106N. For example, if one or more of discrete signals 106a...106N indicates a fault condition, discrete signal 206a will indicate the fault condition. If none of the discrete signals 106a, . . . , 106N indicate a fault condition, then the discrete signal 206a will not indicate a fault condition.

[0061]

[0064] The processor 116 may also transmit other relevant information regarding the battery to the controller 204. For example, the processor 116 may determine the amount of energy that the battery assembly 100 may release to the load 224, and the processor 116 may transmit such information to the controller 204 using the digital signal 206b.

[0062]

[0065] In another example, the processor 116 may determine the amount of energy that the battery assembly 100 can absorb (e.g., during a charging phase and / or during a phase in which the load 224 acts as a generator and sends energy back to the battery assembly 100), and the processor 116 may transmit such information to the controller 204 using the digital signal 206b.

[0063]

[0066] In one embodiment, system 200 includes a DC / DC converter 220 that receives DC power from battery assembly 100, for example, through switches 209a and 209b. For example, switch 209a is proximal to (and may even be included in or part of) battery assembly 100, and switch 209b is proximal to (and may even be included in or part of) DC / DC converter 220. In one example, DC / DC converter 220 functions to step up or step down the voltage level of the DC voltage from battery assembly 100.

[0064]

[0067] In one embodiment, system 200 further includes an inverter 222 that receives DC power from battery assembly 100 through DC / DC converter 220. In one example, inverter 222 converts the DC power from converter 220 to AC power, which is supplied to load 224. In one example, load 224 is a motor. Note that in one example, DC / DC converter 220 may not be present, for example, in cases where DC voltage conversion is not used. Similarly, in one example, inverter 222 may not be present, for example, in cases where load 224 may receive a DC voltage.

[0065]

[0068] System 200 further includes switches 209c and / or 209d between DC / DC converter 220 and inverter 222, and switches 209e and / or 209f between inverter 222 and load 224. Thus, switches 209a, 209b, 209c, 209d, 209e, and 209f are present between battery assembly 100 and load 224. Switches 209a, ..., 209f may be, for example, contactors or other suitable types of switches.

[0066]

[0069] In one example, each switch is controlled by a corresponding digital control signal (illustrated using undashed lines) and / or a corresponding discrete signal (illustrated using dotted lines). In one example, the control signals are generated by controller 204. For example, as illustrated in FIG. 2, switch 209a is controlled by digital control signal 212a and / or discrete control signal 212b, switch 209b is controlled by digital control signal 213a and / or discrete control signal 213b, switch 209c is controlled by digital control signal 214a and / or discrete control signal 214b, switch 209d is controlled by digital control signal 215a and / or discrete control signal 215b, switch 209e is controlled by digital control signal 216a and / or discrete control signal 216b, and switch 209f is controlled by digital control signal 217a and / or discrete control signal 217b.

[0067]

[0070] The digital control signals 212a, 213a, ..., 217a may be transmitted over a corresponding digital bus, such as a CAN bus, or may be transmitted wirelessly using an appropriate wireless protocol (e.g., Bluetooth or Wi-Fi). Meanwhile, the discrete control signals 212b, 213b, ..., 217b may be transmitted over a corresponding discrete bus (such as an analog signal bus) or may be transmitted wirelessly. Sending the same information to the switch over the digital bus and the discrete bus increases the reliability and redundancy of the information transmission to the switch.

[0068]

[0071] In one embodiment, control signals 212a, ..., 217a, 212b, ..., 217b are generated by controller 204, for example, at least in part in response to signals 206a and / or 206b. For example, upon detection of a fault condition in battery assembly 100 (e.g., based on monitoring discrete signal 206a and / or digital signal 206b), controller 204 issues a command (e.g., via control signals 212a, ..., 217a, 212b, ..., 217b) to open one or more of switches 209 of system 200.

[0069]

[0072] For example, during normal operation of the system 200, the switches 209a...209f are in a closed or conducting state, and the battery assembly 100 supplies power to the load 224, for example, through the switches 209a...209f, the converter 220, and the inverter 222. However, one or more fault conditions may occur in the battery assembly 100. The fault condition(s) may be, for example, an under-voltage condition, an over-voltage condition, an over-temperature condition, a gas release event, and / or a pressure relief event detected by one or more of the sensors 108a, 108, 134, 135 described above with respect to FIG. 1 . There may be one or more additional sensors to detect one or more additional fault conditions, such as, for example, an over-current fault condition, an over-charge fault condition, an under-charge fault condition, an under-temperature fault condition, etc. A discrete signal 206a and / or a digital signal 206b from the processor 116 to the controller 204 may provide an indication of the fault condition(s).

[0070]

[0073] In one embodiment, in response to signals 106a and / or 206b indicating one or more such fault conditions, controller 204 transitions one or more of control signals 212a...217a, 212b...217b to transition one or more of switches 209a...209f from a closed (conducting) state to an open or disconnected state (non-conducting or otherwise not passing energy). In one example, controller 204 is a fault detection and mitigation controller that monitors the health of battery assembly 100, monitors battery assembly 100 for fault conditions, and mitigates any detected fault condition(s) by issuing control signals 212a...217a, 212b...217b to open one or more of switches 209a...209f and disconnect battery assembly 100 from load 224 accordingly.

[0071]

[0074] In one embodiment, system 200 includes component 205, which may be a human-interactive component (such as an aircraft cockpit display) or an engineering workstation. A human (such as an aircraft pilot) may interact with component 205 and monitor it for the fault conditions described above. For example, instead of or in addition to controller 204 automatically issuing commands to open one or more of switches 209a...209f, a human interacting with component 205 may also manually issue commands to open one or more of switches 209a...209f. As described above, the commands to open one or more of switches 209a...209f may be in the form of digital control signals 212a...217a and / or discrete signals 212b...217b.

[0072]

[0075] 3 illustrates a system 300 at least partially similar to system 200 of FIG. 2 , according to one embodiment of the present disclosure, where system 300 of FIG. 3 includes multiple battery assemblies 100 a, 100 b that power corresponding loads 224, 324. For example, system 200 of FIG. 2 included the single battery assembly 100 of FIG. 1. In contrast, system 300 of FIG. 3 includes a first battery assembly 100 a and a second battery assembly 100 b, each of which may be similar to battery system 100 of FIG. 1. Some of the components of battery assembly 100 a are illustrated in FIG. 3 , while only processor 116 of battery assembly 100 b is illustrated in FIG. 3 .

[0073]

[0076] As illustrated, battery assembly 100b supplies power to load 324 through DC / DC converter 320, inverter 322, and switches 309a...309f, each of which is similar to the corresponding components of system 200 of Figure 2. Further, similar to Figure 2, switches 309a...309f are controlled by digital signals 312a...317a and / or discrete signals 312b...317b issued by controller 204, as illustrated in Figure 3. Figure 3 will be apparent based on the description of Figure 2.

[0074] [Method]

[0077] FIG. 4 illustrates a flowchart illustrating a method 400 for operating the battery assembly 100 of FIGS. 1-3 and the battery systems 200 and 300 of FIGS. 2 and 3 according to one embodiment of the present disclosure.

[0075]

[0078] At 404 of the method 400, the battery assembly 100 supplies power to the load 224, for example, through one or more of the switches 209a, ..., 209f, the DC / DC converter 220, and / or the inverter 222, as illustrated in Figures 2 and 3.

[0076]

[0079] Method 400 proceeds from 404 to 408, where the first processor 136 of the first battery module 104a receives a first sensed signal (e.g., either sensed signal 119a or 119b) from a first sensor (e.g., a corresponding one of sensors 134 or 135) of the first battery module 104a. Similarly, the second processor 136 of the second battery module 104b receives a second sensed signal from a second sensor of the second battery module 104b, as described above with respect to FIG.

[0077]

[0080] The method 400 proceeds from 408 to 412, where the first processor generates a first digital signal 105a and a first discrete signal 106a based on the first sensed signal. Similarly, the second processor generates a second digital signal 105b and a second discrete signal 106b based on the second sensed signal, as described above with respect to FIG.

[0078]

[0081] Method 400 proceeds from 412 to 416, where third processor 116 receives first and second digital signals 105a, 105b, first and second discrete signals 106a, 106b, and a discrete sensing signal (e.g., either discrete sensing signal 117a or 117b) from a third sensor (e.g., either sensor 108a or 108b). In one example, third processor 116 is within battery assembly 100 and external to each of the first and second battery modules, as shown. Also, at 416, third processor 116 generates a third digital signal based on discrete sensing signal 117a or 117b. In this manner, the digital signal generated by third processor 116 corresponds to discrete sensing signal 117a or 117b.

[0079]

[0082] Method 400 proceeds from 416 to 420, where the third processor transmits (i) the first, second, and third digital signals, (ii) the first and second discrete signals, and (iii) the discrete sense signal to controller 204 external to the battery assembly. For example, the first, second, and third digital signals are transmitted as digital signals 206b. The first and second discrete signals and the discrete sense signal are transmitted as discrete signals 206a, as described above with respect to FIG. 2.

[0080]

[0083] The method 400 proceeds from 420 to 424, where the controller 204 detects whether a battery warning and / or fault event has occurred based on, for example, monitoring (i) the first, second, and third digital signals, (ii) the first and second discrete signals, and (iii) the discrete sensing signal, as described above with respect to FIG. 2 .

[0081]

[0084] If 424 is "No" (e.g., no battery warning and / or failure events have been detected), method 400 loops back to 408, where controller 204 continues monitoring (408-420) and detecting (424). Note that operations at 404, 408, 412, 416, and 420 occur continuously during normal or normal operation of battery assembly 100, e.g., until a positive detection occurs at 424.

[0082]

[0085] If 424 is "Yes" (e.g., a battery warning and / or fault event is detected), method 400 proceeds from 424 to 428. At 428, controller 204 causes at least one of switches 209a,...,209f to open by issuing digital and discrete control signals, as described above with respect to FIG.

[0083]

[0086] It should be noted that the processes in method 400 are shown in a particular order for ease of explanation. However, according to some embodiments, one or more of the processes may be performed in a different order or may not be performed at all (and may therefore be optional). Numerous variations on method 400 and techniques described herein will be apparent in light of this disclosure.

[0084] Further Examples

[0087] The following examples relate to further embodiments, from which numerous permutations and configurations are apparent.

[0085]

[0088] Example 1. A battery assembly comprising: a housing; first and second battery modules within the housing, wherein each of the first and second battery modules comprises: (i) an array of battery cells; (ii) a first sensor configured to measure a first parameter of the corresponding battery module; and (iii) a first processor configured to receive first sensor data from the first sensor of the corresponding battery module; and a second sensor within the housing and configured to measure a second parameter of the battery assembly, wherein the second sensor is configured to measure a second parameter of the first and second battery modules. a second processor within the housing configured to (i) receive first processor data from the first processor of the first battery module and from the first processor of the second battery module, (ii) receive second sensor data from the second sensor, and (iii) send controller input data to a controller external to the battery assembly, wherein the controller input data is based on (A) the first processor data from the first processors of the first and second battery modules and (B) the second sensor data.

[0086]

[0089] Example 2. A battery assembly as described in Example 1, wherein the first processor of the first battery module is configured to generate a discrete signal and a digital signal based on a sensing signal received from a first sensor of the first battery module, and to transmit the discrete signal and the digital signal to the second processor as first processor data from the first processor of the first battery module.

[0087]

[0090] Example 3. The battery assembly of example 2, wherein the discrete signal indicates whether the sense signal indicates a fault condition, and the digital signal indicates a value of a first parameter represented by the sense signal.

[0088]

[0091] Example 4. The battery assembly of Example 3, wherein the first parameter is one of a voltage output by the array of battery cells of the first battery module and the fault condition is an under-voltage condition or an over-voltage condition, or the first parameter is a temperature and the fault condition is an over-temperature condition.

[0089]

[0092] Example 5. A battery assembly as described in any one of Examples 1 to 4, wherein the data received by the second processor from the second sensor is in the form of a discrete sensing signal received from the second sensor, a first state of the discrete sensing signal indicating a fault condition and a second state of the discrete sensing signal indicating that no fault condition has been sensed.

[0090]

[0093] Example 6. The battery assembly of Example 5, wherein the fault condition is at least one of a gas release event in which gas release above a threshold level is detected within the battery assembly, or a pressure relief event in which a pressure relief device within the enclosure releases gas pressure from the enclosure.

[0091]

[0094] Example 7. A system comprising: a battery assembly comprising: (i) a plurality of battery cells; (ii) a sensor configured to measure a parameter within the battery assembly and generate sensory data; and (iii) a processor configured to send a first discrete signal and a first digital signal to a controller, wherein the first discrete signal and the first digital signal are based on the sensory data; a controller external to the battery assembly; a load, wherein the battery assembly is configured to supply power to the load; and a switch between the battery assembly and the load, wherein the controller is configured to send a second discrete signal and a second digital signal to the switch to cause the switch to disconnect the load from the battery assembly in response to the first discrete signal and / or the first digital signal indicating a fault condition within the battery assembly.

[0092]

[0095] Example 8. The system of Example 7, wherein the switch is a first switch, and the system further comprises: a voltage converter for receiving a first voltage from the battery assembly and outputting a second voltage, wherein the voltage converter is coupled between the battery assembly and the load; and a second switch, wherein the first switch is between the battery assembly and the voltage converter and the second switch is between the voltage converter and the load.

[0093]

[0096] Example 9. The system of Example 8, wherein the controller is further configured to, in response to the first discrete signal and / or the first digital signal indicating a fault condition in the battery assembly, send a third discrete signal and a third digital signal to the second switch to cause the second switch to disconnect the load from the voltage converter.

[0094]

[0097] Example 10. The system described in any one of Examples 7 to 9, wherein the sensor is a first sensor, the processor is a first processor, the sensor data is first sensor data, and the battery assembly comprises: a first battery module comprising: (i) a first cooling plate; (ii) a first subset of a plurality of battery cells arranged adjacent to the first cooling plate; (iii) the first sensor; and (iv) a second processor configured to receive the first sensor data from the first sensor; and a second battery module comprising: (i) a second cooling plate; (ii) a second subset of a plurality of battery cells arranged adjacent to the second cooling plate; (iii) the second sensor; and (iv) a third processor configured to receive the second sensor data from the second sensor.

[0095]

[0098] Example 11. The system of Example 10, wherein the first battery module further comprises a third cooling plate, and wherein the individual battery cells of the first subset of the plurality of battery cells extend laterally from near the first cooling plate to near the third cooling plate.

[0096]

[0099] Example 12. A system described in any one of Examples 10 to 11, wherein the second processor is configured to generate a first discrete signal and a first digital signal and transmit the first discrete signal and the first digital signal to the first processor.

[0097]

[0100] Example 13. The system of any one of Examples 10-12, wherein the first battery module, the second battery module, and the processor are within a housing.

[0098]

[0101] Example 14. The system described in Example 13, wherein the parameter is a first parameter, and the system further comprises a third sensor within the battery assembly and external to each of the first battery module and the second battery module, the third sensor configured to (i) measure the second parameter, (ii) generate a third discrete signal indicative of the second parameter, and (iii) transmit the third discrete signal to the first processor.

[0099]

[0102] Example 15. The system of Example 14, wherein the third sensor is one of (i) a gas release sensor configured to sense a gas release event in one or more battery cells among the plurality of battery cells, or (ii) a pressure relief sensor that indicates whether a pressure relief device in the enclosure has released gas pressure from the enclosure.

[0100]

[0103] Example 16. A system described in any one of Examples 10 to 15, wherein the first sensor is one of (i) a voltage sensor configured to sense the voltage of one or more battery cells of a first subset of the plurality of battery cells of the first battery module, or (ii) a temperature sensor for measuring the temperature of the first battery module.

[0101]

[0104] Example 17. A method comprising: receiving, by a first processor of a first battery module, a first sensing signal from a first sensor of the first battery module; generating, by the first processor, a first digital signal and a first discrete signal based on the first sensing signal; receiving, by a second processor of a second battery module, a second sensing signal from a second sensor of the second battery module; generating, by the second processor, a second digital signal and a second discrete signal based on the second sensing signal; and receiving, by a third processor included within a housing of the battery assembly, the first and second digital signals and the first and second discrete signals, wherein the battery assembly comprises the first battery module, the second battery module, and the third processor.

[0102]

[0105] Example 18. The method of Example 17, further comprising receiving, by a third processor, a discrete sensing signal from a third sensor within the battery assembly and external to each of the first battery module and the second battery module, and generating, by the third processor, a third digital signal based on the discrete sensing signal.

[0103]

[0106] Example 19. The method of Example 18, further comprising transmitting, by a third processor and to a controller external to the battery assembly, (i) the first, second, and third digital signals, (ii) the first and second discrete signals, and (iii) the discrete sensing signal.

[0104]

[0107] Example 20. The method of Example 19, further comprising causing, by the controller, a switch between the battery assembly and the load to open in response to at least one of the first, second, and third digital signals, the first and second discrete signals, and the discrete sensing signal indicating a fault condition in the battery assembly.

[0105]

[0108] The foregoing description of example embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the disclosure be limited not by this detailed description, but rather by the claims appended hereto. Future applications claiming priority to this application may claim the disclosed subject matter differently and may generally include any set of one or more limitations as variously disclosed or otherwise set forth herein.

Claims

1. 1. A battery assembly comprising: The housing and first and second battery modules within the housing, wherein each of the first battery module and the second battery module comprises: (i) an array of battery cells; (ii) a first sensor configured to measure a first parameter of a corresponding battery module; and (iii) a first processor configured to receive first sensor data from the first sensor of the corresponding battery module; a second sensor within the housing and configured to measure a second parameter of the battery assembly, the second sensor being external to the first and second battery modules; and a second processor within the housing configured to (i) receive first processor data from the first processor of the first battery module and from the first processor of the second battery module, (ii) receive second sensor data from the second sensor, and (iii) send controller input data to a controller external to the battery assembly, the controller input data being based on (A) the first processor data from the first processors of the first and second battery modules and (B) the second sensor data; A battery assembly comprising:

2. The first processor of the first battery module generating a discrete signal and a digital signal based on the sensed signal received from the first sensor of the first battery module; transmitting the discrete signal and the digital signal as the first processor data from the first processor of the first battery module to the second processor; The battery assembly of claim 1 configured to:

3. 3. The battery assembly of claim 2, wherein the discrete signal indicates whether the sense signal indicates a fault condition, and the digital signal indicates a value of the first parameter represented by the sense signal.

4. the first parameter is a voltage output by the array of battery cells of the first battery module and the fault condition is an under-voltage condition or an over-voltage condition; or the first parameter is a temperature and the fault condition is an over-temperature condition; 4. The battery assembly of claim 3, wherein:

5. 2. The battery assembly of claim 1, wherein the data received by the second processor from the second sensor is in the form of a discrete sense signal received from the second sensor, a first state of the discrete sense signal indicating a fault condition and a second state of the discrete sense signal indicating that a fault condition has not been sensed.

6. The fault condition is a gassing event in which gassing above a threshold level is detected within the battery assembly; or a pressure relief event in which a pressure relief device within the enclosure releases gas pressure from the enclosure; 6. The battery assembly of claim 5, wherein the battery assembly is at least one of:

7. 1. A system comprising: a battery assembly comprising: (i) a plurality of battery cells; (ii) a sensor configured to measure a parameter within the battery assembly and generate sensory data; and (iii) a processor configured to send a first discrete signal and a first digital signal to a controller, wherein the first discrete signal and the first digital signal are based on the sensory data; the controller external to the battery assembly; a load, wherein the battery assembly is configured to supply power to the load; and a switch between the battery assembly and the load; wherein the controller is configured, in response to the first discrete signal and / or the first digital signal indicating a fault condition in the battery assembly, to send a second discrete signal and a second digital signal to the switch to cause the switch to disconnect the load from the battery assembly.

8. the switch is a first switch, and the system a voltage converter for receiving a first voltage from the battery assembly and outputting a second voltage, wherein the voltage converter is coupled between the battery assembly and the load; and a second switch, wherein the first switch is between the battery assembly and the voltage converter and the second switch is between the voltage converter and the load; and The system of claim 7 further comprising:

9. 9. The system of claim 8, wherein the controller is further configured, in response to the first discrete signal and / or the first digital signal indicating the fault condition in the battery assembly, to send a third discrete signal and a third digital signal to the second switch to cause the second switch to disconnect the load from the voltage converter.

10. The sensor is a first sensor, the processor is a first processor, the sensed data is first sensed data, and the battery assembly is a first battery module comprising: (i) a first cold plate; (ii) a first subset of the plurality of battery cells disposed adjacent to the first cold plate; (iii) the first sensor; and (iv) a second processor configured to receive the first sensed data from the first sensor; a second battery module comprising: (i) a second cold plate; (ii) a second subset of the plurality of battery cells disposed adjacent to the second cold plate; (iii) a second sensor; and (iv) a third processor configured to receive second sensed data from the second sensor; The system of claim 7, comprising:

11. 11. The system of claim 10, wherein the first battery module further comprises a third cold plate, and wherein individual battery cells of the first subset of the plurality of battery cells extend laterally from near the first cold plate to near the third cold plate.

12. 11. The system of claim 10, wherein the second processor is configured to generate the first discrete signal and the first digital signal and to transmit the first discrete signal and the first digital signal to the first processor.

13. The system of claim 10 , wherein the first battery module, the second battery module, and the processor are within an enclosure.

14. The parameter is a first parameter, and the system: and a third sensor within the battery assembly and external to each of the first battery module and the second battery module, the third sensor configured to (i) measure a second parameter, (ii) generate a third discrete signal indicative of the second parameter, and (iii) transmit the third discrete signal to the first processor. The system of claim 13.

15. 15. The system of claim 14, wherein the third sensor is one of: (i) a gas release sensor configured to sense a gas release event in one or more battery cells of the plurality of battery cells; or (ii) a pressure relief sensor that indicates whether a pressure relief device in the enclosure has released gas pressure from the enclosure.

16. 11. The system of claim 10, wherein the first sensor is one of: (i) a voltage sensor configured to sense a voltage of one or more battery cells of the first subset of the plurality of battery cells of the first battery module; or (ii) a temperature sensor for measuring a temperature of the first battery module.

17. 1. A method comprising: receiving, by a first processor of a first battery module, a first sensed signal from a first sensor of the first battery module; generating, by the first processor, a first digital signal and a first discrete signal based on the first sensed signal; receiving, by a second processor of a second battery module, a second sensed signal from a second sensor of the second battery module; generating, by the second processor, a second digital signal and a second discrete signal based on the second sensed signal; receiving the first and second digital signals and the first and second discrete signals by a third processor contained within a housing of a battery assembly, wherein the battery assembly comprises the first battery module, the second battery module, and the third processor; A method for providing the above.

18. receiving, by the third processor, discrete sensed signals from a third sensor within the battery assembly and external to each of the first battery module and the second battery module; generating, by the third processor, a third digital signal based on the discrete sensed signals; 20. The method of claim 17, further comprising:

19. transmitting, by the third processor and to a controller external to the battery assembly, (i) the first, second, and third digital signals, (ii) the first and second discrete signals, and (iii) the discrete sensed signals.

20. The method of claim 18, further comprising:

20. causing, by the controller, a switch between the battery assembly and a load to open in response to at least one of the first, second, and third digital signals, the first and second discrete signals, and the discrete sense signal indicating a fault condition within the battery assembly.

20. The method of claim 19 further comprising:

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