Balancing system for rechargeable energy storage assembly with multiple parallel units
11133680 · 2021-09-28
Assignee
Inventors
Cpc classification
H02J7/0014
ELECTRICITY
H02J7/0048
ELECTRICITY
B60L58/13
PERFORMING OPERATIONS; TRANSPORTING
Y02T10/70
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H02J7/00047
ELECTRICITY
Y02T90/12
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B60L50/64
PERFORMING OPERATIONS; TRANSPORTING
B60L58/14
PERFORMING OPERATIONS; TRANSPORTING
H02J7/00712
ELECTRICITY
Y02T10/7072
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
H02J7/00
ELECTRICITY
B60L58/14
PERFORMING OPERATIONS; TRANSPORTING
B60L58/13
PERFORMING OPERATIONS; TRANSPORTING
Abstract
System and method of dynamically balancing a rechargeable energy storage assembly having two or more respective units, a respective switch for each of the respective units and at least one sensor. The system includes a controller configured to control operation of the respective switch. The respective switch is configured to enable a respective circuit connection to the respective units when in an ON state and disable the respective circuit connection when in an OFF state. The respective units are characterized by a respective state of charge obtained based in part on the at least one sensor. A controller is configured to selectively employ at least one of a plurality of charging modes to charge one or more of the respective units, through operation of the respective switch. The plurality of charging modes includes a rest charging mode, a rapid initial charging mode and a rapid final charging mode.
Claims
1. A system of dynamically balancing a rechargeable energy storage assembly having at least two respective units connected in parallel, a respective switch for each of the respective units and at least one sensor, the system comprising: a controller configured to control operation of the respective switch and including a processor and tangible, non-transitory memory on which instructions are recorded; wherein the respective switch includes an ON state and an OFF state, the respective switch being configured to enable a respective circuit connection to one of the respective units in the ON state and disable the respective circuit connection in the OFF state; wherein the respective units are characterized by a respective state of charge obtained based in part on the at least one sensor; wherein the respective units include a first unit and a second unit, the controller being configured to determine a first state of charge (SOC1) for the first unit and a second state of charge (SOC2) for the second unit; wherein execution of the instructions by the processor causes the controller to employ at least one of a plurality of charging modes through operation of the respective switch to charge the respective units; wherein the plurality of charging modes includes a rest charging mode, a rapid initial charging mode and a rapid final charging mode; and wherein in the rest charging mode, the controller is configured to turn the respective switch of the first unit and the respective switch of the second unit to the ON state and charge with a first constant charging current until the first unit and the second unit are fully charged when an absolute value of a difference between the first state of charge (SOC1) and the second state of charge (SOC2) is less than a first predefined constant (C1); wherein in the rapid initial charging mode, the controller is configured to: set a target state of charge at a third threshold (T3) and turn the respective switch of each of the respective units to the ON state and charge with a second constant charging current; and apply an integration control scheme to a specific one of the respective units and selectively charge until fully charged, when an absolute value of a difference between a respective state of charge (SOCi) of a specific one of the respective units and the third threshold (T3) is less than a third predefined constant (C3).
2. The system of claim 1, wherein: the rest charging mode is configured to selectively employ a first constant charging current and the rapid initial charging mode is configured to selectively employ the second constant charging current, the second constant charging current being greater than the first constant charging current; and the rapid final charging mode is configured to selectively employ a constant voltage.
3. The system of claim 1, wherein: in the rest charging mode, the controller is configured to turn the respective switch associated with a higher value of the respective state of charge to the OFF state and selectively charge the respective unit associated with a lower value of the respective state of charge, when the difference between the first state of charge (SOC1) and the second state of charge (SOC2) is more than or equal to the first predefined constant (C1).
4. The system of claim 1, wherein in the rapid final charging mode, the controller is configured to: turn the respective switch of each of the respective units to the ON state and charge with a constant voltage when the respective state of charge of at least one of the respective units is less than a second threshold (T.sub.2); and turn the respective switch associated with the at least one of the respective units to the OFF state and selectively charge remaining ones of the respective units when the respective state of charge of at least one of the respective units is greater than a maximum energy value (E.sub.max).
5. The system of claim 4, wherein the second threshold (T.sub.2) is within 5% of a magnitude of the maximum energy value (E.sub.max).
6. The system of claim 1, wherein the integration control scheme includes: selecting a target state of charge as a maximum of the respective state of charge of the respective units; and defining a disparity factor as a difference between a target state of charge and the respective state of charge of the specific one of the respective units; and shifting an applied voltage to the specific one of the respective units from a negative value to a positive value when the disparity factor is above a disparity threshold, the disparity threshold being less than zero.
7. The system of claim 1, wherein the third threshold (T.sub.3) is between 50% and 70%, inclusive, and the third predefined constant (C.sub.3) is between 5% and 7%, inclusive.
8. The system of claim 1, wherein the respective units include a first unit and a second unit, further comprising: a discharging mode during which the controller is configured to keep the respective switch of the first unit and the respective switch of the second unit in the ON state and discharge the first unit and the second unit when a load demand current (I.sub.d) is more than or equal to a rated current limit (I.sub.L1) defined by the first unit; and in the discharging mode when the load demand current (I.sub.d) is less than the rated current limit (I.sub.L1) of the first unit, the first unit having a higher state of charge relative to the second unit, the controller being configured to: turn the respective switch of the first unit to the ON state, turn the respective switch of the second unit to the OFF state and discharge the first unit; set a target state of charge as the respective state of charge of the second unit and apply an integration control scheme to the respective switch of the first unit; and turn the respective switch of the first unit and the respective switch of the second unit to the ON state and discharge the first unit and the second unit when an absolute value of a difference between the respective state of charge of the first unit and the respective state of charge of the second unit is less than a fourth predefined constant (C.sub.4).
9. A method of dynamically balancing a rechargeable energy storage assembly having two or more respective units connected in parallel, a respective switch for each of the respective units, at least one sensor and a controller with a processor and tangible, non-transitory memory, the method comprising: controlling operation of the respective switch via the controller, including enabling a respective circuit connection to one of the respective units with the respective switch in an ON state and disabling the respective circuit connection with the respective switch in an OFF state, the respective units including a first unit and a second unit; obtaining a first state of charge (SOC1) for the first unit and a second state of charge (SOC2) for the second unit, based in part on the at least one sensor; employing at least one of a plurality of charging modes to charge the respective units, via the respective switch and the controller, the plurality of charging modes including a rest charging mode, a rapid initial charging mode and a rapid final charging mode; in the rest charging mode, turning the respective switch of the first unit and the respective switch of the second unit to the ON state and charging with a first constant charging current until the first unit and the second unit are fully charged when an absolute value of a difference between the first state of charge (SOC1) and the second state of charge (SOC2) is less than a first predefined constant (C1), via the controller; setting a target state of charge at a third threshold (T3) in the rapid initial charging mode, turning the respective switch of each of the respective units to the ON state and charging with a second constant charging current; and applying an integration control scheme to a specific one of the respective units and selectively charging until fully charged, in the rapid initial charging mode, when an absolute value of a difference between the respective state of charge (SOC1) of a specific one of the respective units and the third threshold (T3) is less than a third predefined constant (C3).
10. The method of claim 9, further comprising: configuring the rest charging mode to selectively employ a first constant charging current; configuring the rapid initial charging mode to selectively employ the second constant charging current, the second constant charging current being greater than the first constant charging current; and configuring the rapid final charging mode to selectively employ a constant voltage.
11. The method of claim 9, in the rest charging mode, turning the respective switch associated with a higher value of the respective state of charge to the OFF state and selectively charging the respective unit associated with a lower value of the respective state of charge, when the difference between the first state of charge (SOC1) and the second state of charge (SOC2) is more than or equal to the first predefined constant (C1).
12. The method of claim 9, further comprising in the rapid final charging mode: turning the respective switch of each of the respective units to the ON state and charging with a constant voltage when the respective state of charge of at least one of the respective units is less than a second threshold (T.sub.2), via the controller; and turning the respective switch associated with the at least one of the respective units to the OFF state and selectively charging remaining ones of the respective units when the respective state of charge of at least one of the respective units is greater than a maximum energy value (E.sub.max), via the controller.
13. The method of claim 11, further comprising in the rapid initial charging mode: setting the second constant charging current to be greater than the first constant charging current.
14. The method of claim 13, wherein the integration control scheme includes: selecting a target state of charge as a maximum of the respective state of charge of the respective units; and defining a disparity factor as a difference between the target state of charge and the respective state of charge of the specific one of the respective units; and shifting an applied voltage to the specific one of the respective units from a negative value to a positive value when the disparity factor is above a disparity threshold, the disparity threshold being less than zero.
15. The method of claim 14, wherein the third threshold (T.sub.3) is between 50% and 70%, inclusive, and the third predefined constant (C.sub.3) is between 5% and 7%, inclusive.
16. The method of claim 9, further comprising: in a discharging mode, turning the respective switch of the first unit and the respective switch of the second unit to the ON state and discharging the first unit and the second unit when a load demand current (I.sub.d) is more than or equal to a rated current limit (I.sub.L1) defined by the first unit; in the discharging mode, when the load demand current (I.sub.d) is less than the rated current limit (I.sub.L1) of the first unit, the first unit having a higher state of charge relative to the second unit: turning the respective switch of the first unit to the ON state, turn the respective switch of the second unit to the OFF state and discharging the first unit; setting the target state of charge as the respective state of charge of the second unit and applying an integration control scheme to the respective switch of the first unit; and turning the respective switch of the first unit and the respective switch of the second unit to the ON state and discharging the first unit and the second unit when an absolute value of a difference between the respective state of charge of the first unit and the respective state of charge of the second unit is less than a fourth predefined constant (C.sub.4).
17. A system of dynamically balancing a rechargeable energy storage assembly having at least two respective units connected in parallel, a respective switch for each of the respective units and at least one sensor, the system comprising: a controller configured to control operation of the respective switch and including a processor and tangible, non-transitory memory on which instructions are recorded; wherein the respective switch includes an ON state and an OFF state, the respective switch being configured to enable a respective circuit connection to one of the respective units in the ON state and disable the respective circuit connection in the OFF state; wherein the respective units are characterized by a respective state of charge obtained based in part on the at least one sensor; wherein the respective units include a first unit and a second unit, the controller being configured to determine a first state of charge (SOC.sub.1) for the first unit and a second state of charge (SOC.sub.2) for the second unit; wherein execution of the instructions by the processor causes the controller to employ at least one of a plurality of charging modes through operation of the respective switch to charge the respective units, the plurality of charging modes including a rest charging mode, a rapid initial charging mode and a rapid final charging mode; wherein in the rest charging mode, the controller is configured to turn the respective switch of the first unit and the respective switch of the second unit to the ON state and charge with a first constant charging current until the first unit and the second unit are fully charged when an absolute value of a difference between the first state of charge (SOC1) and the second state of charge (SOC2) is less than a first predefined constant (C1); wherein in the rapid initial charging mode where there are exactly two of the respective units, the controller is configured to: turn the respective switch of the first unit and the respective switch of the second unit to the ON state and charge both with a second constant charging current, when the first state of charge (SOC1) for the first unit and the second state of charge (SOC2) for the second unit are both less than a first threshold (T1), the second constant charging current being greater than the first constant charging current; and set a target state of charge and selectively charge the respective unit associated with a lower value of the state of charge until charged to the target state of charge, when an absolute value of a difference between the first state of charge (SOC1) and the second state of charge (SOC2) is greater than a second predefined constant (C2).
18. The system of claim 17, wherein the first threshold (T.sub.1) is 50%.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(10) Referring to the drawings, wherein like reference numbers refer to like components,
(11) The rechargeable energy storage assembly 11 may include rechargeable units having different chemistries, including but not limited to, lithium-ion, lithium-iron, nickel metal hydride and lead acid batteries. Referring to
(12) Referring to
(13) The controller C is configured to employ at least one of a plurality of charging modes to charge the respective units U. The plurality of charging modes includes a rest charging mode 100, a rapid initial charging mode 200, an alternate rapid initial charging mode 300 and a rapid final charging mode 400, respectively described below with reference to
(14) Each of the respective units U is operatively connected with a respective switch S having an ON state and an OFF state. The respective switch S is configured to enable a respective circuit connection when in an ON state and disable the respective circuit connection when in an OFF state. Referring to
(15) Operation of the respective switches S is controlled by the controller C. As described below, the respective switches S and control logic are used to selectively cut-off high or low energy ones of the respective units U to balance the assembly 11 based on the level of state of charge differences among the respective units U and charge/discharge load demands. The respective switches S may be composed of semi-conductors. In one example, the respective switches S are silicon MOSFET switches. Other switches available to those skilled in the art may be employed.
(16) The respective units U are characterized by a respective state of charge obtained based in part on at least one sensor, such as for example, a first sensor 26 and a second sensor 28 shown in
(17) The rest charging mode 100, rapid initial charging mode 200, alternate rapid initial charging mode 300, rapid final charging mode 400 and discharge mode 500 need not be applied in the specific order recited herein and may be dynamically executed. Furthermore, it is to be understood that some steps may be eliminated. As used herein, the terms ‘dynamic’ and ‘dynamically’ describe steps or processes that are executed in real-time and are characterized by monitoring or otherwise determining states of parameters and regularly or periodically updating the states of the parameters during execution of a routine or between iterations of execution of the routine. The rest charging mode 100, rapid initial charging mode 200, alternate rapid initial charging mode 300, and rapid final charging mode 400 may be concurrently executed by the controller C or may be selected by a user or operator of the rechargeable energy storage assembly 11.
(18) Referring now to
(19) Per block 104 of
(20) If not, the rest charging mode 100 proceeds from block 104 to block 108, where the controller C is programmed to turn the respective switch S associated with a higher value of the respective state of charge to the OFF state and selectively charge (per block 110) the respective unit U associated with a lower value of the respective state of charge. Thus, if the first unit 12 has a higher value of the respective state of charge, the first switch S.sub.1 is turned to the OFF state and the second unit 14 is charged. The rest charging mode 100 loops back to block 104.
(21) The rest charging mode 100 is further illustrated with respect to
(22) Referring now to
(23) Proceeding to block 206 from block 204, the controller C is configured to determine if an absolute value of a difference between the first state of charge (SOC.sub.1) and the second state of charge (SOC.sub.2) is greater than a second predefined constant (C.sub.2). When this is the case, per block 208, the controller C is configured to set a target state of charge and selectively charge the respective unit U associated with a lower value of the state of charge until charged to the target state of charge. When this is not the case, the rapid initial charging mode 200 loops back (as indicated by line 207) to block 204. In one example, the first threshold (T.sub.1) is selected to be 50%.
(24) Referring to
(25) Referring to
(26) Referring to
(27) Referring now to
(28) Per block 508, the controller C is configured to determine if an absolute value of a difference between the respective state of charge (SOC.sub.1) of the first unit 12 and the respective state of charge (SOC.sub.2) of the second unit 14 is less than a fourth predefined constant (C.sub.4). If so, discharging mode 500 proceeds to block 510, turning the respective switch S.sub.1 of the first unit 12 and the respective switch S.sub.2 of the second unit 14 in the ON state and discharge the first unit 12 and the second unit 14. If not, the discharging mode 500 loops back to block 502, as indicated by line 509.
(29) In summary, the system 10 (via execution of at least one of the modes 100, 200, 300, 400, 500) robustly creates a balance of the state of charge amongst the respective units U. The system 10 provides a technical advantage of reducing internal power dissipation in the rechargeable energy storage assembly 11 as well as efficiently controlling charging power and discharging power. Accordingly, the system 10 improves the functioning of the rechargeable energy storage assembly 11. The thresholds T.sub.1, T.sub.2, T.sub.3 and predefined constants C.sub.1, C.sub.2, C.sub.3, C.sub.4 may be obtained through calibration in a laboratory or test cell and selected based on the application at hand.
(30) The flowcharts in
(31) The controller C of
(32) Look-up tables, databases, data repositories or other data stores described herein may include various kinds of mechanisms for storing, accessing, and retrieving various kinds of data, including a hierarchical database, a set of files in a file system, an application database in a proprietary format, a relational database management system (RDBMS), etc. Each such data store may be included within a computing device employing a computer operating system such as one of those mentioned above, and may be accessed via a network in one or more of a variety of manners. A file system may be accessible from a computer operating system, and may include files stored in various formats. An RDBMS may employ the Structured Query Language (SQL) in addition to a language for creating, storing, editing, and executing stored procedures, such as the PL/SQL language mentioned above.
(33) The detailed description and the drawings or FIGS. are supportive and descriptive of the disclosure, but the scope of the disclosure is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed disclosure have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims. Furthermore, the embodiments shown in the drawings or the characteristics of various embodiments mentioned in the present description are not necessarily to be understood as embodiments independent of each other. Rather, it is possible that each of the characteristics described in one of the examples of an embodiment can be combined with one or a plurality of other desired characteristics from other embodiments, resulting in other embodiments not described in words or by reference to the drawings. Accordingly, such other embodiments fall within the framework of the scope of the appended claims.