Battery Monitoring Controller With Deterministic Cell Data Scheduling
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Solution Overview
Problem
Existing battery management systems face challenges in reliability and scalability due to non-deterministic processing, variable latency, and unreliability in wired and wireless communication networks, which can lead to undetected faults and hazards in high-risk applications.
Innovation Solution
Implementing a battery management system with deterministic processing by using dual core lockstep processors, redundant ADCs, and error detection/correction mechanisms, along with a synchronized data transmission schedule to ensure reliable and scalable communication between monitoring devices and a communications controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional processing methods with interrupts and external memory access are used, then device complexity is reduced, but reliability deteriorates due to non-deterministic errors
Solution Approach 1:
The system divides processing into deterministic and non-deterministic segments. Critical safety-related processing is isolated in a deterministic execution environment that excludes interrupts, external memory access, and stack operations. Non-critical functions operate in a separate non-deterministic environment, allowing the system to maintain complexity while ensuring reliability for safety-critical operations.
Solution Approach 2:
A communications controller acts as an intermediary between monitoring devices and the battery management unit. This intermediary handles all communications and data processing in a deterministic manner, mediating between the complex monitoring devices and the safety-critical battery management unit, thereby isolating potential sources of non-deterministic errors.
2Reliability
If deterministic processing is implemented by restricting processors, then reliability is improved, but device complexity increases
Solution Approach 1:
The processing architecture is segmented into deterministic and non-deterministic domains. The deterministic domain includes restricted processors that execute safety-critical code without interrupts or external memory access, while non-critical functions operate in a separate domain with full processing capabilities. This segmentation allows deterministic processing to improve reliability without requiring complete system redesign.
Solution Approach 2:
The system uses redundant ADCs (analog-to-digital converters) that operate in parallel to convert sensor signals. These redundant conversion paths provide deterministic, verified results without requiring complex processing logic in the main processor, thereby improving reliability through redundancy rather than through complex deterministic processing mechanisms.
3Productivity
If monitoring devices transmit data continuously, then productivity is improved, but loss of time increases due to variable latency in communication networks
Solution Approach 1:
The communications controller implements periodic data collection cycles with predetermined time intervals. During each cycle, the controller sequentially queries monitoring devices and collects measurements in a structured manner. This periodic approach ensures that all devices are sampled regularly (maintaining productivity) while the fixed cycle structure eliminates variable latency (improving time predictability).
Solution Approach 2:
The system pre-allocates communication time slots and establishes predetermined query sequences before data collection begins. This preliminary structuring of communication patterns ensures that data transmission follows a known, deterministic schedule, eliminating runtime variability in latency while maintaining continuous monitoring coverage.
4Ease of operation
If wired and wireless communication networks are used for data transmission, then ease of operation is improved, but reliability deteriorates due to network unreliability
Solution Approach 1:
The communications controller serves as a deterministic intermediary between the unreliable wireless/wired networks and the safety-critical battery management unit. It implements error detection and correction protocols, validates received data, and ensures that only verified measurements are forwarded to the battery management unit. This intermediary layer shields the safety-critical system from network unreliability while maintaining ease of operation through wireless connectivity.
Solution Approach 2:
The system implements feedback mechanisms where the communications controller verifies data integrity through checksums, error detection codes, and acknowledgment protocols. When transmission errors occur, the system requests retransmission of affected data packets. This feedback loop maintains reliability by ensuring data accuracy despite the use of unreliable wireless communication channels.
Data Source
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AI summary
Communications controller (15) is provided operable to receive and process measurements of battery cells (22-1... 22-N) of a battery system received from monitoring devices (10-1... 10-N). Monitoring devices (10-1... 10-N) may each comprise: one or more sensors (31, 32, 33) operable to obtain measurements of battery cells (22-1... 22-N); transmitter (30) operable to transmit obtained measurements to communications controller (15); and processor (39, 52) operable to process obtained measurements and cause the obtained measurements to be reported to communications controller (15) in accordance with a predetermined schedule. Monitoring devices (10-1... 10-N) may be configured to report measurements in a deterministic manner which is independent of triggering of any interrupts, external memory access steps or the use of a stack.