Battery Module Testing

Abstract

Testing of the battery module can be performed using monitoring electronics attached to the battery module. A stimulus can be applied to the battery module and then removed. After removal of the stimulus, the monitoring electronics can collect signals from the monitoring electronics that reflect parameters of the battery module when relaxed to a non-stimulated state. The stimulus can be provided by test equipment or components of a system in which the battery module with the attached monitoring electronics is implemented. The monitoring electronics attached to the battery module can provide autonomous recording of signals associated with the battery module that can provide data regarding the condition of the battery module or one or more batteries included in the battery module.

Description

[Technical Field]

[0001] Related Applications This application claims the benefit of priority to U.S. Provisional Application No. 62 / 994,652, filed March 25, 2020, and U.S. Non-Provisional Application No. 17 / 021,682, filed September 15, 2020, which applications are incorporated herein by reference in their entireties.

[0002] This document relates to measurement devices and methods, and in particular to battery measurement devices and methods. [Background technology]

[0003] Electrical impedance spectroscopy (EIS) is the measurement of electrochemical impedance. Electrochemical impedance is typically measured by applying an AC (alternating current) signal, such as a sinusoidal test voltage or current, to an electrochemical cell under test and then measuring the current through the electrochemical cell. EIS uses the measurement of impedance over a suitable frequency range. This can provide a useful technique for investigating the electrical properties of a wide variety of materials and devices, such as batteries.

[0004] EIS testing after module fabrication is not typically performed today, as batteries can be placed in modules and then used as a power source in devices. The conventional procedure for removing defects in battery units is to:

[0005] The voltage of the battery module is measured, the battery module is stored for several weeks, and then the battery voltage is measured again. If the voltage drop is abnormal, the battery is discarded. Advances in battery measurement technology can enhance battery technology and its applications. Summary of the Invention

[0006] Devices having structures for measuring one or more parameters of a battery module or one or more batteries of a battery module can be implemented in a variety of applications. Testing of a battery module can be performed using monitoring electronics attached to the battery module, where a stimulus is applied to the battery module and then removed. After removal of the stimulus, the monitoring electronics can collect signals from the monitoring electronics that reflect the parameters of the battery module when relaxed to a non-stimulated state. The stimulus can be provided by test equipment or components of a system in which the battery module with the attached monitoring electronics is implemented. The monitoring electronics attached to the battery module can provide autonomous recording of signals associated with the battery module, which can provide data regarding the condition of the battery module or one or more batteries included in the battery module.

[0007] For example, in certain embodiments, a method may be provided that discloses a method of battery testing, including applying a stimulus to a battery module, the battery module having one or more batteries, removing the stimulus from the battery module, turning off the battery module, autonomously recording signals from the battery module using monitoring electronics attached to the battery module after turning off the battery module and removing the stimulus from the battery module, and outputting the recorded signals from which one or more electrochemical or electrical parameters of the battery module or one or more batteries disposed within the battery module are calculated using the recorded signals.

[0008] In certain embodiments, a system may be provided that discloses a battery module having one or more batteries; monitoring electronics attached to the battery module for monitoring a response of the batteries of the battery module to a stimulus applied to the batteries; and a controller configured to perform actions including turning off use of the battery module, which action includes removing the stimulus to the battery module; autonomously recording signals from the battery module using the monitoring electronics after turning off use of the battery module and removing the stimulus to the battery module; and outputting the recorded signals from which one or more electrochemical parameters or one or more electrical parameters of the battery module or one or more batteries disposed within the battery module are calculated using the recorded signals.

[0009] In certain embodiments, a system may be provided that discloses a battery module having one or more batteries; means for monitoring a response of the batteries of the battery module to a stimulus applied to the batteries; means for autonomously recording a signal from the battery module in response to the means for monitoring the response of the batteries to identify an off state of the battery module, including removal of the stimulus to the batteries; and means for outputting the recorded signal and calculating therefrom one or more electrochemical parameters or one or more electrical parameters of the battery module or one or more batteries disposed within the battery module using the recorded signal. [Brief explanation of the drawings]

[0010] The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document. The drawings are not necessarily drawn to scale. [Figure 1]1 illustrates an exemplary method flow for battery module testing using battery test equipment as a stimulus and autonomous recorder of measurement signals via electronics attached to the battery module, according to various embodiments. [Figure 2] 1 illustrates an exemplary method flow for battery module testing using battery test equipment as a stimulus and autonomous recorder of measurement signals via electronics attached to the battery module, according to various embodiments. [Figure 3] 1 illustrates an exemplary method flow for battery module testing using battery test equipment as a stimulus and autonomous recorder of measurement signals via electronics attached to the battery module, according to various embodiments. [Figure 4] 1 illustrates an exemplary method flow for battery module testing using battery test equipment as a stimulus and autonomous recorder of measurement signals via electronics attached to the battery module, according to various embodiments. [Figure 5] 1 illustrates an exemplary method flow for battery module testing using battery test equipment as a stimulus and autonomous recorder of measurement signals via electronics attached to the battery module, according to various embodiments. [Figure 6] 1 illustrates an exemplary method flow for battery module testing using battery test equipment as a stimulus and autonomous recorder of measurement signals via electronics attached to the battery module, according to various embodiments. [Figure 7] 1 illustrates an exemplary battery pack in a vehicle, according to various embodiments. [Figure 8] 1 is a flow chart illustrating an exemplary method for testing a battery, according to various embodiments. [Figure 9] FIG. 1 is a block diagram of features of an exemplary system having a battery module with monitoring electronics attached to the battery module, in accordance with various embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0011] In various embodiments, battery module EIS measurements can be accomplished using battery test equipment as a stimulus and autonomous recording of voltage via electronics attached to the module. This measurement method, combined with battery test equipment and autonomous battery monitoring, can perform EIS analysis of the battery. Using autonomous measurements, batteries can be quickly tested at high volume and then moved to storage where monitoring can continue for a relatively long period of time.

[0012] An exemplary measurement procedure for a battery module can be performed in the following manner: A stimulus to the battery module can be applied via test equipment. Such test equipment includes, but is not limited to, the battery module end of line test equipment. Once application of the stimulus is complete, the battery module is removed from the test equipment. Electronics attached to the battery module are used to autonomously record one or more of voltage, temperature, and impedance. The electronics can periodically measure the battery module to conserve energy. The measurement electronics can be powered by the battery module. Using the known stimulus and the recorded parameters, electrochemical or other parameters of the battery module or one or more batteries can be calculated.

[0013] In various embodiments, autonomous measurements of a battery module are performed in response to a stimulus provided by test equipment. The autonomous measurements can be performed after the stimulus is applied and after the battery is removed from the test equipment. This is a superior procedure to traditional use of test equipment to measure battery parameters because a battery's response to the stimulus typically requires a long settling time. It is inefficient to keep the test equipment on a given battery module during the settling time. For example, in the case of an automotive assembly line for electric vehicle battery modules, test times must be very short. As taught herein, autonomous measurements allow measurements to continue offline, freeing up the equipment. Other assembly lines can be implemented in a similar manner for battery modules for other devices with battery-based electrical functionality. Vehicles can include, but are not limited to, trucks, buses, ships, airplanes, motorcycles, robots, trains, or other implements that move as part of their function.

[0014] 1-6 illustrate one embodiment of an exemplary method flow for battery module testing using battery test equipment to provide stimulation and autonomous recording of measurement signals via electronics attached to the battery module. Battery module testing can include electrochemical impedance spectroscopy measurements. FIG. 1 illustrates a point in the manufacturing flow where one or more battery cells 105-1, 105-2, 105-3, and 105-4 are formed into a battery module 110. The battery module can contain more or less than four battery cells.

[0015] 2 illustrates a point in the manufacturing flow where battery monitoring electronics 115 are added to the battery module 110 to form a battery module 120 with monitoring electronics. The monitoring electronics 115 is electrically coupled to the battery module 110 and one or more battery cells 105-1, 105-2, 105-3, and 105-4 to perform measurements of these structures. The monitoring electronics 115 may include a wireless communication device 116 for transmitting data measured or signals collected by the monitoring electronics 115. The measured data or signals collected may be sent to a device or system external to the battery module 120. The monitoring electronics 115 may be implemented as one or more battery monitoring electronic units attachable to one or more battery cells 105-1, 105-2, 105-3, and 105-4 formed within the battery module 110. In this exemplary method, the battery monitoring electronics may autonomously measure some electrical parameter of the battery module 120 or one or more battery cells 105-1, 105-2, 105-3, and 105-4 that includes the monitoring electronics. For example, battery cell voltage, temperature, or impedance may be measured.

[0016] 3 illustrates a point in the manufacturing flow where the battery module 120 with monitoring electronics is stimulated by production test equipment 125. The production test equipment 125 can be high-volume production test equipment. Standard production test equipment can be used to provide the stimulation. The battery module 120 with monitoring electronics can be charged and / or discharged at least once. This stimulation by the production test equipment can be known, measured, or inferred.

[0017] 4 illustrates a point in the manufacturing method where the applied stimulus is removed from the battery module with monitoring electronics 120. At this point, the monitoring electronics 115 autonomously records the battery electrical signal. For example, this autonomous measurement can occur during shipping or storage of the battery module with monitoring electronics 120. Such shipping or storage can be separate from inclusion in the application device.

[0018] To deliver the stimulus, the battery module 120 with its monitoring electronics is energized and may take several hours to relax to its native state. The monitoring electronics 115 may continue to autonomously measure electrical parameters of the battery module 120 and record the signals from which these electrical parameters are derived during the relaxation period. The battery module 120 may be shipped to a warehouse, and the battery monitoring electronics 115 may continue to perform these autonomous measurements until the batteries are fully or substantially relaxed, which may take, for example, 12 to 24 hours or more. The autonomous measurements may be controlled by one or more processing devices and memories housed within the monitoring electronics 115. The monitoring electronics 115 may be capable of measuring individual batteries of the battery module 120.

[0019] FIG. 5 illustrates how signals recorded within the monitoring electronics 115 can be wirelessly transmitted to a receiving device or later retrieved from the monitoring electronics 115's memory. The receiving device can be a local information technology (IT) system or a non-local IT system 130, such as, but not limited to, a cloud-based IT system. IT systems can include data processing systems, information systems, record-keeping systems, communication systems, telecommunications systems, account management systems, inventory management systems, other process-based systems, and internet websites, all of which can be electronic or optoelectronic-based systems. Such systems include associated computer programs, software, databases, firmware, hardware, and related documentation. Wireless transmission can occur using any one of several wireless transmission protocols. In some embodiments, wireless communication can occur using a transmission protocol suitable for a range of 5 to 10 meters. However, wireless transmission is not limited to a range of 5 to 10 meters. In some embodiments, where data is later retrieved from the monitoring electronics' memory, data transmission can occur via a wired connection, such as, but not limited to, a universal serial bus (USB) connection. The short-range wireless communication and USB connection may be coupled to one or more communication networks, which may include a local area network (LAN) or a wide area network (WAN).

[0020] FIG. 6 illustrates a point in the method where EIS characteristics of a battery module 120 or one or more battery cells of a battery module 120 are calculated in a local IT system or non-local IT system 130 providing analysis 135. The characteristics may be EIS characteristics. Such calculations may be based on data recorded by the monitoring electronics 115, as shown in FIG. 4, and known stimuli provided by the test equipment 125, as shown in FIG. 3. Stimulation and relaxation of the battery module 120 provide several of the electrochemical parameters of the battery module 120. The measured response to the stimuli over the relaxation period allows the EIS parameters of the battery module 120 to be modeled in analysis 135 within the IT system 130. These parameters and modeling may be performed on an individual battery basis in addition to modeling the battery module 120 as a single unit. During measurements over the relaxation period, no production test equipment 120 stimuli are provided to the battery module. In some embodiments, a portion of the analysis of the measurement data may be performed within the monitoring electronics 115.

[0021] The process taught in Figures 1-6 involves measuring characteristics of a battery module or one or more batteries within the battery module by applying a stimulus to the battery module and measuring a signal from the battery module after the stimulus is removed from the battery module while the battery module is not actively being used. The measured signal can be collected before the batteries in the battery module are in a relaxed state, a normal relaxed state associated with an unused battery module. The measured battery module can be stored for later use in various applications.

[0022] A similar process can be used in various applications where a battery module is stimulated and an electrical signal is collected from the battery module with the stimulus removed, and the battery module is not actively used in the application. In these applications, the stimulus can be provided by monitoring electronics using a small amount of power from the battery module in each application that does not use the battery module. In some applications with multiple battery modules, one battery module can be tested with a stimulus provided by another one of the battery modules. For example, applications that do not use battery modules can include applications with idle periods or on and off periods. The off periods in such applications can provide an opportunity to test the battery module or one or more batteries of the battery module as it transitions through a relaxation period.

[0023] 7 illustrates one embodiment of an exemplary battery pack 219 in a vehicle 240. The vehicle 240 may be an electric vehicle. The battery pack 219 may include battery module 220-1, battery module 220-2, battery module 220-3, battery module 220-4, battery module 220-5, battery module 220-6, battery module 220-7, and battery module 220-8. The battery pack 219 may have more or less than eight battery modules. The battery modules 220-1, 220-2, 220-3, 220-4, 220-5, 220-6, 220-7, and 220-8 may be connected in series with terminals HV+ and HV− to provide operating power to the vehicle 240. Each of battery modules 220-1, 220-2, 220-3, 220-4, 220-5, 220-6, 220-7, and 220-8 may be configured as a battery module with monitoring electronics similar to, but not limited to, battery module 120 with monitoring electronics of FIG.

[0024] When vehicle 240 is driven, battery modules 220-1, 220-2, 220-3, 220-4, 220-5, 220-6, 220-7, and 220-8 in pack 219 are energized. When vehicle 240 is turned off, monitoring electronics on battery modules 220-1, 220-2, 220-3, 220-4, 220-5, 220-6, 220-7, and 220-8 can measure battery parameters. The monitoring electronics on battery modules 220-1, 220-2, 220-3, 220-4, 220-5, 220-6, 220-7, and 220-8 can measure battery parameters even when the vehicle's BMS (battery management system) controller is turned off or is unable to issue commands to the monitoring electronics. The monitoring electronics may be able to measure autonomously. The measured parameters may include parameters such as voltage, temperature, and impedance. Signals related to these parameters may also be collected within the vehicle BMS system of the vehicle 240. The monitoring electronics on the battery modules 220-1, 220-2, 220-3, 220-4, 220-5, 220-6, 220-7, and 220-8 may send data wirelessly or via wires to the engine control unit (ECU) 250 of the vehicle 240. This data may be transmitted when the vehicle or the BMS controller is turned back on. The ECU is the vehicle's internal computer that monitors and reacts to changes occurring in the vehicle's systems. Wireless data transfer to the ECU 250 may be implemented using a wireless collector 245. The wireless collector 245 may be connected to the ECU 250 via a wired connection or wirelessly. In some examples, when vehicle 240 is off, vehicle ECU 250 may be activated by monitoring electronics in one or more of battery modules 220-1, 220-2, 220-3, 220-4, 220-5, 220-6, 220-7, and 220-8 or by wireless collector 245. Data may be processed within vehicle 240 or sent to cloud 260 for processing. Data may be stored within the BMS of vehicle 240 for later access, such as for standard maintenance inspections.

[0025] Typically, the term "cloud," in relation to data processing and communications, refers to a data center filled with servers connected to the Internet. However, the cloud can refer to any network or combination of networks. The cloud can include a wide area network (WAN), such as the public Internet or a private, national, or global network, and can also include a local area network (LAN) within an organization that provides the services of the data center. In addition, the term "cloud computing" refers to software and services performed for users by these servers; typically, users are unaware of the physical location of the servers or data center. Furthermore, data centers can be distributed entities. Cloud computing can provide shared computer processing resources and data to computers and other devices on demand over an associated network.

[0026] EIS analysis can include processing data collected by the monitoring electronics of a battery module to detect anomalies. A battery module anomaly can be data for a battery in the battery module that differs from data for other batteries in the battery module. A battery module anomaly can be data for a parameter that differs significantly from past data for that parameter for the battery module. Anomalies can be a response to an abnormal stimulus by the battery module or one or more batteries in the battery module.

[0027] EIS analysis can involve processing data collected by the battery module's monitoring electronics to determine the battery module's hidden state, state of charge (SOC), and state of health (SOH). EIS analysis can be applied to small and large battery modules, such as, but not limited to, large battery modules or groups of large battery modules used in electric vehicles. A battery's hidden state is a state that is difficult to measure directly. The hidden state can be determined based on measured data and a database that converts observable data to a hidden state. The measured and determined hidden state regarding voltage and temperature can be used in one or more algorithms to calculate SOC and SOH and evaluate whether the battery and battery module are at a safe operating temperature.

[0028] The EIS analysis can include processing data collected by the battery module's monitoring electronics to model the battery module or one or more batteries of the battery module based on the observational data collected by the battery module's monitoring electronics. The modeling can include creating a small signal electrical model. The electrical model can be responsive to generate associated impedances. The hidden state of the battery, SOC, and SOH can be determined based on the generated impedances and a database, which can be used to convert one or more impedances to the hidden state.

[0029] The processed data collected by the battery module's monitoring electronics can be used in several different ways. The processed data can be used to provide alerts regarding battery degradation and to characterize the health of the battery. For example, as described with respect to FIG. 7 , in a battery module with monitoring electronics used in a vehicle, in response to a determination of battery degradation, a battery degradation alert can be generated on a display in the vehicle. A characterization of the health of the battery module or its battery can also be generated on a display in the vehicle. The indication of battery degradation and health can be used for applications outside of the vehicle.

[0030] The processed data can be used in manufacturing applications to: remove the abnormal battery modules from a supply chain in response to determining that one or more battery modules have an anomaly; and in inventory systems to grade and sort battery modules based on processing data from battery testing as taught herein.

[0031] FIG. 8 is a flowchart illustrating an exemplary embodiment of a method 800 for battery testing. At 810, a stimulus is applied to a battery module, the battery module having one or more batteries. At 820, the battery module is turned off from use, including removing the stimulus from the battery module. At 830, after turning off use of the battery module and removing the stimulus from the battery module, signals from the battery module are autonomously recorded using monitoring electronics attached to the battery module. Autonomously recording signals from the battery module may include recording the voltage, temperature, or impedance of the battery module or one or more batteries. The signals from the battery module may be autonomously recorded during a period including turning off use of the battery module and removing the stimulus from the battery module until completion or substantial completion of relaxation of the battery module from the application of the stimulus. Autonomous recording of signals may be performed continuously or periodically during this period. Completion of relaxation of the battery module from the application of the stimulus may be the next on-use of the battery module, such as in a vehicle or other device that operates with on- and off-cycle periods. Monitoring signals may also be collected during use of the battery module.

[0032] At 840, the recorded signals are output, from which one or more electrochemical or electrical parameters of the battery module or one or more batteries disposed within the battery module are calculated using the recorded signals. The recorded signals may be wirelessly transmitted to a receiving device for analyzing data from the recorded signals. The one or more electrochemical or electrical parameters of the battery module or one or more batteries disposed within the battery module may be calculated using a processing device coupled to the receiving device. Alternatively, this calculation may be performed in conjunction with monitoring electronics. An electrochemical impedance spectroscopy characteristic of the battery module or one or more batteries may be calculated based on data from the recorded signals and the stimulus.

[0033] Method 800, or variations of methods similar to method 800, may include several different embodiments that may be combined depending on the application of such method and / or the architecture of the system in which such method is implemented. Such methods may include applying a stimulus to a battery module, such as applying a stimulus to the battery module using test equipment, and deactivating the battery module, such as removing the stimulus from the battery module from the test equipment. One or more batteries may be formed in the battery module before applying the stimulus to the battery module or one or more batteries. Applying the stimulus to the battery module using the test equipment may include charging and discharging one or more batteries of the battery module. Signals from the battery module may be autonomously recorded during a period of time that includes from removal of the battery module from the test equipment to completion or substantial completion of relaxation of the battery module from the application of the stimulus. The recorded signals may be retrieved from the memory of the monitoring electronics after removal from the test equipment and after the battery module has relaxed from the applied stimulus. The recorded signals may be retrieved from the monitoring electronics and wirelessly transmitted to an analytical device.

[0034] Variations of method 800, or methods similar to method 800, can include providing a stimulus to the battery module, such as exciting the battery module while the battery module is operational in the vehicle, and turning off the battery module, such as removing the stimulus to the battery module while the vehicle is off. Method 800, or methods similar to method 800, can be applied to other devices that operate on battery power, where the device goes through on and off periods. These on and off periods allow for testing of the battery module or individual batteries during a relaxation period after the on stimulus is removed.

[0035] Variations of method 800, or methods similar to method 800, can include detecting anomalies from recorded signals or determining a hidden state of one or more of the battery modules or batteries based on the recorded signals and a database that converts observable data to hidden states. Variations can include modeling one or more of the battery modules or batteries based on the recorded signals, including creating an electrical model, responding the electrical model, generating an impedance from the response of the electrical model, and determining a hidden state of one or more of the battery modules or batteries based on the generated impedance and a database that converts the impedance to hidden states.

[0036] Variations of method 800, or methods similar to method 800, may include processing the recorded signals to provide a battery health characterization to a display. In response to determining battery degradation, the processing may include generating a battery degradation alert. Variations may include processing the recorded signals to provide a quality grade of the battery module to a display. In response to determining an anomaly associated with the battery module, an identification of the battery module as the anomaly battery module may be generated.

[0037] In various embodiments, a non-transitory machine-readable storage device, such as a computer-readable non-transitory medium, can include instructions stored thereon that, when executed by a machine, cause the machine to perform operations that include one or more characteristics similar to or identical to characteristics of the methods and techniques described with respect to method 800, variations thereof, and / or other methods or functions taught herein, such as those associated with FIGS. 1-9. The physical structures of such instructions can be operated by one or more processors. Execution of these physical structures can cause the machine to perform various operations.

[0038] A non-transitory machine-readable medium having stored thereon instructions for testing a battery module, which, when executed by one or more processors, can cause a system to perform operations including applying a stimulus to a battery module, the battery module having one or more batteries, removing the stimulus from the battery module, turning off use of the battery module, including removing the stimulus from the battery module, autonomously recording signals from the battery module using monitoring electronics attached to the battery module after turning off use of the battery module and removing the stimulus from the battery module, and outputting the recorded signals and calculating therefrom one or more electrochemical or electrical parameters of the battery module or one or more batteries disposed within the battery module using the recorded signals. The operations can include controlling the application of the stimulus to the battery module using test equipment, turning off use of the battery module, and removing the stimulus from the battery module by removing the stimulus from and communicating with the test equipment. The operations can include recording the voltage, temperature, or impedance of the one or more batteries. The operation may include turning off use of the battery module and autonomously recording signals from the battery module during a period including removing a stimulus to the battery module and completing relaxation of the battery module from applying the stimulus.

[0039] The instructions may be executed by one or more processors to perform operations of wirelessly transmitting the recorded signals to a receiving device and analyzing data from the recorded signals. The operations may also include retrieving the recorded signals from a memory of the monitoring electronics after providing the stimulus, removing them from coupling to the test equipment, and at a time after the battery module has relaxed from the applied stimulus. The operations may include calculating an electrochemical impedance spectroscopy signature of the battery module or one or more batteries based on the data from the recorded signals and the stimulus.

[0040] Variations of the operations executable by one or more processors may include several different embodiments that may be combined depending on the application of such a non-transitory machine-readable storage device and / or the architecture of the system in which such a non-transitory machine-readable storage device is implemented. Such operations may include applying a stimulus to the battery module to energize the battery module while the battery module is operational in the vehicle, and turning off use of the battery module, including removing the stimulus to the battery module while the vehicle is off. Variations of the operations executable by one or more processors may be applied to other devices that operate on battery power, where the device goes through on and off periods. These on and off periods allow for testing of the battery module or individual batteries during a relaxation period after the on stimulus is removed.

[0041] Variations of the operations can include detecting anomalies from the recorded signals or determining a hidden state of one or more of the battery modules or batteries based on the recorded signals and a database that converts observable data to a hidden state. Variations of the operations can include modeling one or more of the battery modules or batteries based on the recorded signals, including creating an electrical model, responding the electrical model, generating an impedance from the response of the electrical model, and determining a hidden state of one or more of the battery modules or batteries based on the generated impedance and a database that converts the impedance to a hidden state.

[0042] In various embodiments, a system can include a battery module having one or more batteries, monitoring electronics attached to the battery module for monitoring a response of the batteries of the battery module to a stimulus applied to the batteries, and a controller configured to perform operations including turning off use of the battery module including removing the stimulus to the battery module, autonomously recording signals from the battery module using the monitoring electronics after turning off use of the battery module and removing the stimulus to the battery module, and outputting the recorded signals from which one or more electrochemical or electrical parameters of the battery module or one or more batteries disposed within the battery module can be calculated using the recorded signals.

[0043] Variations of such a system may include several different embodiments that may be combined depending on the application of such a system and / or the architecture in which such a system is implemented. Such a system may include test equipment for providing stimulation to the battery. The autonomously recorded signals may be the voltage, temperature, or impedance of one or more batteries. Such a system may include a transmitter for wirelessly transmitting the recorded signals to a receiving device for analyzing data from the recorded signals.

[0044] A variation of such a system may include a controller operable to autonomously record signals from the battery module during a period of time that includes turning off use of the battery module and removing a stimulus to the battery module through completion of relaxation of the battery module from the application of the stimulus. Such a system may include a processing device configured to perform operations including: modeling one or more of the battery modules or batteries based on the recorded signals, including creating an electrical model; causing the electrical model to respond; generating an impedance from the response of the electrical model; and determining a hidden state of one or more of the battery modules or batteries based on the generated impedance and a database that converts the impedance to a hidden state. Such a system may be implemented to perform the functions of the methods and techniques described with respect to method 800, variations thereof, methods similar to method 800, and / or features of other methods or functions taught herein.

[0045] In various embodiments, the system can include a battery module having one or more batteries, means for monitoring a response of the batteries in the battery module to a stimulus applied to the batteries, means for autonomously recording signals from the battery module in response to the means for monitoring the response of the batteries to identify a turn-off of the battery module, including removal of the stimulus to the batteries, and means for outputting the recorded signals and calculating therefrom one or more electrochemical or electrical parameters of the battery module or one or more batteries disposed within the battery module using the recorded signals. The autonomous recording of signals from the battery module can occur during a period including turning off the battery and removing the stimulus to the battery to completion of relaxation of the battery from the application of the stimulus.

[0046] Variations of such a system may include several different embodiments that may be combined depending on the application of such a system and / or the architecture in which such a system is implemented. Such a system may include means for processing the recorded signals, which is operable to provide, in response to determining battery degradation, a battery health characterization, including an alert of the battery degradation, to a display. Variations of such a system may include means for processing the recorded signals, which is operable to provide, in response to determining an anomaly associated with the battery module, a quality grade of the battery module, including an identification of the battery module as the anomaly. Such a system may be implemented to perform the functions of the methods and techniques described with respect to method 800, variations thereof, methods similar to method 800, and / or characteristics of other methods or functions taught herein.

[0047] FIG. 9 is a block diagram of an exemplary embodiment of a system 900 having battery modules 920-1 through 920-N. The system 900 includes monitoring electronics 915-1 through 915-N (attached to battery modules 920-1 through 920-N, respectively). The battery modules 920-1 through 920-N (with monitoring electronics 915-1 through 915-N) may be implemented in some devices using one or more battery modules, each battery module having one or more batteries. The monitoring electronics 915-1 through 915-N can be used as taught herein when testing the battery modules 920-1 through 920-N. The monitoring electronics 915-1 through 915-N can be used to track the SOC, SOH, voltage parameters, temperature, or a combination thereof, of the battery modules 920-1 through 920-N or one or more batteries included in the battery modules 920-1 through 920-N. Battery modules 920-1 through 920-N and monitoring electronics 915-1 through 915-N may be implemented in an electric vehicle, a vehicle with battery-based electrical functionality, or other device. The vehicle may include a truck, bus, boat, airplane, motorcycle, robot, train, or other appliance that moves as part of its functionality.

[0048] System 900 may be a networked system in which battery modules 920-1 through 920-N (with monitoring electronics 915-1 through 915-N) may be located in a manufacturing storage area after testing of battery modules 920-1 through 920-N, respectively, or in a device powered by one or more batteries. Battery modules 920-1 through 920-N (with monitoring electronics 915-1 through 915-N) may be implemented similarly to battery module 120 with monitoring electronics of FIG. 4 or battery modules 220-j, j = 1, 2, ... 8 (with monitoring electronics of FIG. 7) (not limited to eight battery modules).

[0049] The system 900 may also include several components, such as one or more processors 952, a memory module 955, a communication unit 958, a data processing unit 954, electronics 954, peripherals 957, a display unit 961, a user interface 962, and a selection device 964. The one or more processors 952 may operate as a single processor or a group of processors. The processors of a group of processors may operate independently according to their assigned functions. The one or more processors 952 may be implemented in one or more application specific integrated circuits (ASICs). The one or more processors 952 may be implemented in one or more digital signal processors (DSPs). In controlling the operation of the components of the system 900 to execute a scheme associated with the function for which the system 900 is designed, the one or more processors 952 may direct the access of data to and from a database.

[0050] The system 900 may include one or more processors 952, memory modules 955, and communication units 958 arranged to operate as processing units to control management of the battery modules 920-1...920-N (with monitoring electronics 915-1...915-N). Additionally, for example, the one or more processors 952, memory modules 955, and communication units 958 may be arranged to adjust operating parameters of the battery modules 920-1...920-N (with monitoring electronics 915-1...915-N). Depending on the application, the communication units 958 may use a combination of wired and wireless communication technologies.

[0051] The memory module 955 can include a database having information, algorithms, and other data that enable the system 900 to operate on data from the battery modules 920-1... 920-N (with monitoring electronics 915-1... 915-N). The database can include information for converting observable data to hidden states. The database can include information for converting impedance generated from modeling to hidden states. Algorithms stored in the memory module 955, including algorithms for calculation and modeling, can be used to extract the SOC, SOH, temperature, and hidden states of the battery modules 920-1... 920-N (with monitoring electronics 915-1... 915-N). These calculation and modeling algorithms can include several different known algorithms. The data processing unit 954 can be implemented as a standalone unit for determining the SOC, SOH, temperature, and hidden states, or the data processing unit 954 can be distributed among components of the system 900, including the memory module 955 and / or the electronics 954.

[0052] The bus 937 provides electrical connectivity between the components of the system 900. The bus 937 may include several different communication channels. When used locally with the battery modules 920-1...920-N, the bus 937 may include an address bus, a data bus, and a control bus, each of which may be independently configured. The bus 937 may be implemented using several different communication media, allowing for distribution of the components of the system 900. Use of the bus 937 may be regulated by one or more processors 952. The bus 937 may operate as part of a communication network for transmitting and receiving signals, including data signals and command and control signals. The bus 937 may be implemented as a distributed bus, including wireless communication links, for the overall operation of the system 900, including several subsystems.

[0053] In various embodiments, peripherals 957 may include drivers for providing voltage and / or current output from battery modules 920-1...920-N (with monitoring electronics 915-1...915-N), additional storage memory, or other control devices (which may operate in conjunction with one or more processors 952 or memory modules 955).

[0054] The display unit 961 can be arranged with instructions stored in the memory module 955 and an available screen display to implement a user interface 962 for managing the operation of the battery modules 920-1... 920-N (with monitoring electronics 915-1... 915-N) and / or components (distributed within the system 900). The display unit 961 can display information about the battery modules 920-1... 920-N or one or more batteries contained therein, obtained through monitoring the battery modules 920-1... 920-N during their relaxation periods. Such information can include, but is not limited to, one or more of battery degradation alerts, battery module quality grades, and battery health characterizations. Such a user interface can operate in conjunction with the communication unit 958 and the bus 937. The display unit 961 can include a video screen or other structure for visually projecting data / information and images. The system 900 may include several selection devices 964 operable with the user interface 962 to provide user input for operating the data processing unit 954 or its equivalent. The selection devices 964 may include touch screens or selection devices operable with the user interface 962 to provide user input for operating the data processing unit 954 or other components of the system 900.

[0055] System 900 can be implemented as test equipment having battery modules 920-1...920-N (with monitoring electronics 915-1...915-N) (which are the workpieces on which such test equipment operates). System 900 can be implemented as test equipment such as test equipment 125 of FIG. 3. System 900 can be implemented at least in part in an apparatus such as, but not limited to, an electric vehicle, a vehicle with battery-based electrical functionality, or other apparatus with off periods of battery use. The following are exemplary embodiments of systems and methods of operation according to the teachings herein.

[0056] An exemplary system 1 having a structure for measuring batteries may include a battery module having one or more batteries; monitoring electronics attached to the battery module for monitoring the response of the batteries of the battery module to a stimulus applied to the batteries; and a controller configured to perform operations including turning off use of the battery module, which includes removing the stimulus to the battery module; autonomously recording signals from the battery module using the monitoring electronics after turning off use of the battery module and removing the stimulus to the battery module; outputting the recorded signals and using the recorded signals to calculate one or more electrochemical parameters or one or more electrical parameters of the battery module or one or more batteries disposed within the battery module. An exemplary system 2 having a structure for measuring a battery may include the characteristics of exemplary system 1 and may include test equipment for providing stimuli to the battery.

[0057] The exemplary system 3 having a structure for measuring a battery can include characteristics of any of the exemplary systems described above and can include autonomously recording signals to include recording voltage, temperature, or impedance of one or more batteries.

[0058] An exemplary system 4 having a structure for measuring a battery can include characteristics of exemplary system 3 or any of the preceding exemplary systems and can include a controller operable to turn off use of the battery module and autonomously record signals from the battery module during a period including from removing a stimulus to the battery module to completing relaxation of the battery module from applying the stimulus.

[0059] An exemplary system 5 having a structure for measuring a battery can include features of exemplary system 3 or any of the exemplary systems described above, and can include a transmitter for wirelessly transmitting the recorded signal to a receiving device for analyzing data from the recorded signal.

[0060] An exemplary system 6 having a structure for measuring a battery may include characteristics of any of the aforementioned exemplary systems and may include a processing device configured to perform operations including modeling one or more of the battery modules or batteries based on recorded signals, including creating an electrical model, causing the electrical model to respond, generating an impedance from the response of the electrical model, and determining a hidden state of one or more of the battery modules or batteries based on the generated impedance and a database that converts the impedance to a hidden state.

[0061] In exemplary system 7, any of the devices associated with exemplary systems 1-6 may further include a machine-readable storage device configured to store instructions as physical states, which may be used to perform one or more operations of the devices and systems. In exemplary system 8, any of exemplary systems 1-7 may be operated by any of exemplary methods 1-17 below.

[0062] An exemplary system 9 having a structure for measuring batteries may include a battery module having one or more batteries, means for monitoring the response of the batteries in the battery module to a stimulus applied to the batteries, means for autonomously recording a signal from the battery module in response to the means for monitoring the response of the batteries to identify a battery module off, including removal of the stimulus to the batteries, and means for outputting the recorded signal and using the recorded signal to calculate therefrom one or more electrochemical parameters or one or more electrical parameters of the battery module or one or more batteries disposed within the battery module.

[0063] An exemplary system 10 having a structure for measuring a battery can include the characteristics of exemplary system 9 and can include means for autonomously recording signals from a battery module, which can include turning off use of the battery and autonomously recording signals from the battery module during a period including from removing a stimulus to the battery to completing relaxation of the battery from applying the stimulus.

[0064] An exemplary system 11 having a structure for measuring a battery may include features of any of the exemplary systems 9 and 10 described above and may include means for processing recorded signals, the means for processing recorded signals operable to provide a characterization of the battery health on a display, including an alert of the battery degradation, in response to a determination of battery degradation.

[0065] An exemplary system 12 having a structure for measuring a battery may include characteristics of any of the exemplary systems 9-11 described above and may include means for processing recorded signals, the means for processing recorded signals operable to provide on a display, in response to determining an anomaly associated with the battery module, a quality grade of the battery module, including an identification of the battery module as being an anomaly battery module.

[0066] In exemplary system 13, any of the devices associated with exemplary systems 9-12 may further include a machine-readable storage device configured to store instructions as physical states, which may be used to perform one or more operations of the devices and systems. In exemplary system 14, any of exemplary systems 9-12 may be operated by any of exemplary methods 1-17 below.

[0067] An exemplary method 1 of battery testing may include applying a stimulus to a battery module, the battery module having one or more batteries; turning off the battery module, including removing the stimulus from the battery module; autonomously recording signals from the battery module using monitoring electronics attached to the battery module after turning off the battery module and removing the stimulus from the battery module; outputting the recorded signals and calculating therefrom one or more electrochemical parameters or one or more electrical parameters of the battery module or one or more batteries disposed within the battery module using the recorded signals.

[0068] An exemplary method 2 of battery testing may include characteristics of exemplary method 1 and may include applying a stimulus to the battery module, including applying a stimulus to the battery module using test equipment; and turning off use of the battery module, including removing the stimulus to the battery module, including removing the stimulus from the test equipment to the battery module.

[0069] An exemplary method 3 of battery testing may include features of any of the exemplary methods described above and may include applying stimuli to the battery module using test equipment, such as charging and discharging one or more batteries of the battery module.

[0070] An exemplary method 4 of battery testing can include features of any of the aforementioned exemplary methods and can include autonomously recording signals from the battery module as they occur during a period including from removal of the battery module from coupling to the test equipment to completion of relaxation of the battery module from applying the stimulus.

[0071] An exemplary method 5 of battery testing can include features of any of the exemplary methods described above and can include retrieving the recorded signal from the memory of the monitoring electronics after removal from coupling to the test equipment and at a time after the battery module has relaxed from the applied stimulus.

[0072] The exemplary method 6 of battery testing may include features of any of the exemplary methods described above and may include calculating one or more electrochemical parameters or one or more electrical parameters of a battery module or one or more batteries disposed within the battery module.

[0073] The exemplary method 7 of battery testing can include features of any of the exemplary methods described above and can include one or more batteries being formed in a battery module prior to applying a stimulus to the battery module or one or more batteries.

[0074] The exemplary method 8 of battery testing can include features of any of the exemplary methods described above and can include autonomously recording signals to include recording voltage, temperature, or impedance of one or more batteries.

[0075] The exemplary method 9 of battery testing can include features of any of the exemplary methods described above and can include autonomously recording the signal, including periodically recording the signal.

[0076] The exemplary method 10 of battery testing may include features of any of the aforementioned exemplary methods and may include turning off use of the battery module and autonomously recording signals from the battery module occurring during a period including from removing a stimulus to the battery module to completing relaxation of the battery module from applying the stimulus.

[0077] The exemplary method 11 of battery testing may include features of any of the exemplary methods described above and may include wirelessly transmitting the recorded signal to a receiving device for analyzing data from the recorded signal.

[0078] The exemplary method 12 of battery testing may include features of any of the aforementioned exemplary methods and may include retrieving the recorded signal from the memory of the monitoring electronics after removal from coupling to the test equipment providing the stimulus and at a time after the battery module has relaxed from the applied stimulus.

[0079] The exemplary method 13 of battery testing can include features of any of the exemplary methods described above and can include calculating electrochemical impedance spectroscopy characteristics of one or more of the battery modules or batteries based on data from the recorded signals and the stimulus.

[0080] The exemplary method 14 of battery testing may include features of any of the exemplary methods described above and may include providing a stimulus to the battery module, such as exciting the battery module while the battery module is operational in the vehicle, and turning off use of the battery module, such as removing the stimulus to the battery module while the vehicle is off.

[0081] The exemplary method 15 of battery testing can include characteristics of any of the aforementioned exemplary methods and can include detecting anomalies from the recorded signals or determining a hidden state of one or more of the battery modules or batteries based on the recorded signals and a database that converts observable data to a hidden state.

[0082] An exemplary method 16 of battery testing may include characteristics of any of the aforementioned exemplary methods and may include modeling one or more of the battery modules or batteries based on the recorded signals, including creating an electrical model; responding the electrical model; generating an impedance from the response of the electrical model; and determining a hidden state of one or more of the battery modules or batteries based on the generated impedance and a database that converts the impedance to a hidden state.

[0083] In exemplary system method 17, any apparatus associated with exemplary methods 1-16 may further include a machine-readable storage device configured to store instructions as physical states, which may be used to perform one or more operations of exemplary methods 1-16 and the apparatus.

[0084] The exemplary method 18 of battery testing can include features of any of the aforementioned exemplary methods of battery testing and can include performing functionality associated with features of any of the exemplary systems 1-14 having a structure for measuring a battery, and features of any of the exemplary systems associated with the figures herein.

[0085] The above detailed description refers, by way of example and not by way of limitation, to the accompanying drawings which show various embodiments that may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice these and other embodiments. Other embodiments may be utilized, and structural, logical, mechanical, and electrical changes may be made to these embodiments. Various embodiments are not necessarily mutually exclusive, as some embodiments may be combined with one or more other embodiments to form new embodiments. Therefore, the above detailed description should not be construed in a limiting sense.

[0086] While specific embodiments have been shown and described herein, it will be understood by those skilled in the art that any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. Various embodiments use permutations and / or combinations of the embodiments described herein. It should be understood that the above description is illustrative and not limiting, and that the phraseology or terminology used herein is for the purpose of description. [Explanation of symbols]

[0087] 105-1 Battery 105-2 Battery 105-3 Battery 105-4 Battery 110 Battery Module 115 Battery monitoring electronic equipment 115 Surveillance electronic equipment 116 Wireless communication devices 120 Battery Module 125 Test Equipment 130 Systems 219 Battery Pack 220-1 Battery Module 220-2 Battery Module 220-3 Battery Module 220-4 Battery Module 220-5 Battery Module 220-6 Battery Module 220-7 Battery Module 220-8 Battery Module 240 Automobiles 245 Wireless Collector 250 Engine Control Unit (ECU) 260 Cloud 900 System 915 Surveillance electronic equipment 915-1 Surveillance electronic equipment 920-1 Battery Module 937 Bus 952 processor 954 Electronic equipment 954 Data Processing Unit 955 memory module 957 Peripherals 958 Communication Unit 961 Display Unit 962 User Interface 964 Select Device

Claims

1. 1. A method of battery testing, comprising: Charging or discharging one or more batteries of the battery module; ceasing charging or discharging one or more batteries of the battery module; After ceasing to charge or discharge one or more batteries of the battery module, using monitoring electronics attached to the battery module, recording signals related to electrical impedance spectroscopy (EIS) parameters of the battery module or the one or more batteries over a relaxation period of the battery module until the battery module returns to its native state; and calculating the EIS parameters of the battery module or the one or more batteries from the recorded signals using a predetermined algorithm.

2. Charging or discharging one or more batteries of the battery module includes charging or discharging one or more batteries of the battery module using test equipment; The method of claim 1 , wherein ceasing to charge or discharge one or more batteries of the battery module comprises removing the battery module from the test equipment.

3. The method of claim 1, wherein recording the signal includes recording the voltage, temperature, or impedance of the one or more batteries.

4. The method of claim 1 , wherein the method includes wirelessly transmitting the recorded signals to a receiving device for analyzing data from the recorded signals.

5. charging or discharging one or more batteries of the battery module includes providing operating power to the vehicle while the battery module is operable in the vehicle; The method of claim 1 , wherein ceasing to charge or discharge one or more batteries of the battery module comprises ceasing to provide operating power to the vehicle.

6. The method comprises: The method of claim 1 , further comprising detecting an abnormality in the battery module or the one or more batteries based on the EIS parameters.

7. 1. A system comprising: a battery module having one or more batteries; monitoring electronics attached to the battery module for monitoring the response of the batteries of the battery module to charging or discharging; A controller configured to perform an operation, the operation comprising: stopping charging or discharging one or more batteries of the battery module; using the monitoring electronics to record signals related to electrical impedance spectroscopy (EIS) parameters of the battery module or the one or more batteries after ceasing charging or discharging of the one or more batteries of the battery module during a relaxation period of the battery module until the battery module returns to its native state; and calculating the EIS parameters of the battery module or the one or more batteries from the recorded signals using a predetermined algorithm.

8. The system comprises: The system of claim 7 including test equipment for charging or discharging the one or more batteries of the battery module.

9. The system of claim 7 , wherein recording a signal comprises recording a voltage, a temperature, or an impedance of the one or more batteries.

10. The system of claim 7 , wherein the system includes a transmitter for wirelessly transmitting the recorded signals to a receiving device for analyzing data from the recorded signals.

11. 1. A system comprising: a battery module having one or more batteries; means for monitoring the response of the batteries of the battery module to charging or discharging; means for recording signals related to electrical impedance spectroscopy (EIS) parameters of the battery module or one or more batteries over a relaxation period of the battery module until the battery module returns to its native state in response to the means for monitoring a response identifying that the charging or discharging has stopped; means for calculating the EIS parameters of the battery module or the one or more batteries from the recorded signals using a predetermined algorithm.

12. 12. The system of claim 11, wherein the system includes means for processing the recorded signals, the means for processing the recorded signals operable to provide, in response to determining battery degradation, a characterization of the battery's health on a display including an alert of the battery degradation.

13. 12. The system of claim 11, wherein the system includes means for processing the recorded signals, and the means for processing the recorded signals is operable to provide to a display, in response to determining an abnormality associated with the battery module, a quality grade of the battery module including an identification of the battery module as being an abnormal battery module.

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