Abstract: Systems and methods for performing low voltage charging of a high voltage, series-connected string of battery modules are disclosed. A battery pack system may include a plurality of battery cells, including one or more groups of battery cells coupled in parallel. A processor may be configured to select a sub-group of battery cells from a group of battery cells for charging separately from other battery cells of the selected group of battery cells. The group of battery cells may be reconfigured to allow charging of the sub-group of battery cells separate from the other battery cells. The sub-group of battery cells may be charged, and then the group of battery cells may be reconfigured to allow operation of the sub-group of battery cells with the other battery cells. During charging, the sub-group of battery cells may be unavailable but other battery cells may continue to discharge.

Abstract: Systems and methods for performing low voltage charging of a high voltage, series-connected string of battery modules are disclosed. A battery pack system may include a plurality of battery cells, including one or more groups of battery cells coupled in parallel. A processor may be configured to select a sub-group of battery cells from a group of battery cells for charging separately from other battery cells of the selected group of battery cells. The group of battery cells may be reconfigured to allow charging of the sub-group of battery cells separate from the other battery cells. The sub-group of battery cells may be charged, and then the group of battery cells may be reconfigured to allow operation of the sub-group of battery cells with the other battery cells. During charging, the sub-group of battery cells may be unavailable but other battery cells may continue to discharge.

Abstract: A battery pack system module may include a module bypass switch for allowing charge current to bypass the battery pack system module. A charge switch and a discharge switch may be coupled with the module bypass switch. When other battery pack system modules are coupled in series with the module, balancing between modules may be achieved by allowing charge current to bypass the unbalanced modules and charge other modules. For example, when an unbalanced module is at a higher level of charge than other modules, a charge switch and a discharge switch in the unbalanced module de-activate and a module bypass switch activates to allow charge current to rapidly bring other modules into balance. The discharge switch and the charge switch allow the charging current to bypass the unbalanced module creating little or no additional heat dissipation.

Abstract: A battery pack system module may include a module bypass switch for allowing charge current to bypass the battery pack system module. The module bypass switch may be activated to divert charging current from the battery pack system module to other battery pack system modules. The charging current may be diverted to bring other battery pack system modules into balance with the battery pack system module. That is, to bring the state of charge of all battery pack system modules into coarse balance. When the module bypass switch is activated, charging current through the module bypass switch may be monitored by a current sensing device such as a current sensing resistor. A microprocessor may receive information about the bypass current level and use the information to determine when to de-activate the module bypass switch. Sensing current through a module bypass switch allows more accurate and quicker inter-module balancing.

Abstract: Battery cells may be monitored and a historical profile of the battery generated. The historical profile may be used to analyze a state-of-health of the battery cell. For example, the historical profile may be used to determine when a battery cell has developed an internal short that creates a safety hazard. The historical profile may include a count of the number of times the battery cell was out of balance and a count of the number of Coulombs the battery cell was out of balance. The number of Coulombs may be counted for a window of time. When the number of Coulombs exceeds a Coulomb threshold, a state-of-health flag may be set for the battery cell. The Coulomb threshold may be adjusted based, in part, on the counted number of times the battery cell is out of balance.

Abstract: A battery pack system module may include a module bypass switch for allowing charge current to bypass the battery pack system module. The module bypass switch may be activated to divert charging current from the battery pack system module to other battery pack system modules. The charging current may be diverted to bring other battery pack system modules into balance with the battery pack system module. That is, to bring the state of charge of all battery pack system modules into coarse balance. When the module bypass switch is activated, charging current through the module bypass switch may be monitored by a current sensing device such as a current sensing resistor. A microprocessor may receive information about the bypass current level and use the information to determine when to de-activate the module bypass switch. Sensing current through a module bypass switch allows more accurate and quicker inter-module balancing.

Abstract: A battery pack system module may include a module bypass switch for allowing charge current to bypass the battery pack system module. The module bypass switch may be activated to divert charging current from the battery pack system module to other battery pack system modules. The charging current may be diverted to bring other battery pack system modules into balance with the battery pack system module. That is, to bring the state of charge of all battery pack system modules into coarse balance. When the module bypass switch is activated, charging current through the module bypass switch may be monitored by a current sensing device such as a current sensing resistor. A microprocessor may receive information about the bypass current level and use the information to determine when to de-activate the module bypass switch. Sensing current through a module bypass switch allows more accurate and quicker inter-module balancing.

Abstract: A battery pack system module may include a module bypass switch for allowing charge current to bypass the battery pack system module. A charge switch and a discharge switch may be coupled with the module bypass switch. When other battery pack system modules are coupled in series with the module, balancing between modules may be achieved by allowing charge current to bypass the unbalanced modules and charge other modules. For example, when an unbalanced module is at a higher level of charge than other modules, a charge switch and a discharge switch in the unbalanced module de-activate and a module bypass switch activates to allow charge current to rapidly bring other modules into balance. The discharge switch and the charge switch allow the charging current to bypass the unbalanced module creating little or no additional heat dissipation.

Abstract: Internal shorts and other failures in lithium-ion battery cells may be detected during balancing of the battery cells. A counter may be used to detect when a battery cell is behaving differently than other battery cells by balancing more or less frequently. The counter may increment each time a battery cell is balanced to the other battery cells. A misbehaving battery cell may be flagged, when the counter exceeds a threshold value, for safety checks before an overheating event occurs. This misbehaving battery cell may be faulty due to an internal short. If the faulty battery cell is not corrected by replacement with a different battery cell or corrected by a user resetting the counter, the misbehaving battery cell may be disconnected to prevent the overheating event.

Abstract: A system for balancing a plurality of battery pack system modules connected in series may include in each battery pack system module a controller configured to detect that the first system module has reached a first state of charge; activate the first charge switch to physically disconnect and to prevent further charging of the first system module after detecting the first state of charge; discharge the plurality of cells after activating the first charge switch to balance the first system module with a second system module coupled to the first system module; de-activate the first charge switch after discharging the plurality of battery cells; and charge the plurality of cells after de-activating the first charge switch.

Abstract: The remaining capacity of a power source, such as a battery, may be monitored with a microprocessor by integrating data received from a current sensor. The microprocessor may measure electrons passing through the battery by sampling the integrator and summing the values recorded from the integrator. Each time the integrator is sampled, the microprocessor may reset the integrator to prevent the integrator from saturating. The microprocessor may sample the integrator when the integrator approaches a predetermined value. The remaining capacity of the battery may be calculated based on calibration values and the sum of electrons measured by the integrator. The remaining capacity may be communicated to remote users through a network and displayed in an executive dashboard.

Abstract: Battery cells may be monitored and a historical profile of the battery generated. The historical profile may be used to analyze a state-of-health of the battery cell. For example, the historical profile may be used to determine when a battery cell has developed an internal short that creates a safety hazard. The historical profile may include a count of the number of times the battery cell was out of balance and a count of the number of Coulombs the battery cell was out of balance. The number of Coulombs may be counted for a window of time. When the number of Coulombs exceeds a Coulomb threshold, a state-of-health flag may be set for the battery cell. The Coulomb threshold may be adjusted based, in part, on the counted number of times the battery cell is out of balance.

Abstract: Battery cells may be monitored and a historical profile of the battery generated. The historical profile may be used to analyze a state-of-health of the battery cell. For example, the historical profile may be used to determine when a battery cell has developed an internal short that creates a safety hazard. The historical profile may include a count of the number of times the battery cell was out of balance and a count of the number of Coulombs the battery cell was out of balance. The number of Coulombs may be counted for a window of time. When the number of Coulombs exceeds a Coulomb threshold, a state-of-health flag may be set for the battery cell. The Coulomb threshold may be adjusted based, in part, on the counted number of times the battery cell is out of balance.

Abstract: A system for balancing a plurality of battery pack system modules connected in series may include in each battery pack system module a controller configured to detect that the first system module has reached a first state of charge; activate the first charge switch to physically disconnect and to prevent further charging of the first system module after detecting the first state of charge; discharge the plurality of cells after activating the first charge switch to balance the first system module with a second system module coupled to the first system module; de-activate the first charge switch after discharging the plurality of battery cells; and charge the plurality of cells after de-activating the first charge switch.

Abstract: A system for balancing a plurality of battery pack system modules connected in series comprising: a plurality of battery pack system modules, wherein a high charge module of the plurality of battery pack system modules has a charge greater than a that of other modules. At least one zener diode connected in series with a current limiting resistor is connected in parallel to the plurality of battery pack system modules. A power source is in communication with a disconnect circuit of at least one of the battery pack system modules. The disconnect circuit is actuated when the battery pack system module reaches a predetermined state of charge. The zener diode enables current from the power source to bypass charged battery pack system modules to charge other battery pack system modules.

Abstract: The remaining capacity of a power source, such as a battery, may be monitored with a microprocessor by integrating data received from a current sensor. The microprocessor may measure electrons passing through the battery by sampling the integrator and summing the values recorded from the integrator. Each time the integrator is sampled, the microprocessor may reset the integrator to prevent the integrator from saturating. The microprocessor may sample the integrator when the integrator approaches a predetermined value. The remaining capacity of the battery may be calculated based on calibration values and the sum of electrons measured by the integrator. The remaining capacity may be communicated to remote users through a network and displayed in an executive dashboard.

Abstract: The remaining capacity of a battery may be monitored with a microprocessor by integrating a voltage measured across a current sense resistor coupled in series with the battery. The microprocessor may measure electrons passing through the battery by sampling the integrator and summing the values recorded from the integrator. Each time the integrator is sampled, the microprocessor may reset the integrator to prevent the integrator from saturating. The remaining capacity of the battery may be calculated based on calibration values and the sum of electrons measured by the integrator. The remaining capacity may be communicating to remote users through a network and displayed in an executive dashboard.

Abstract: A fuel gauge for power supplies having a voltage pre-regulator; a main voltage regulator; a current sense resistor; an integrator with an op amp and capacitor, wherein the integrator receives power from the main voltage regulator, and receives a voltage proportional to current from the current sense resistor; a microprocessor with data storage and a hysteresis circuit, wherein the microprocessor operates in a low power state until activated by the resistor and the microprocessor converts the voltage proportional to current to a monotonic uni-polar representation of an aggregate number of electrons; a resistor disposed between the integrator and the microprocessor for activating the microprocessor from the low power state prior to saturation of the integrator with the voltage proportional to current; and a reset circuit disposed between the microprocessor and the integrator for resetting the monotonic uni-polar representation of an aggregate number of electrons to zero.

Abstract: A system for counting electrons including a power supply producing a current, a fuel gauge in communication with the power supply, a reader with a reader processor and display, wherein the reader is in communication with a microprocessor of the fuel gauge, and wherein the microprocessor transmits to the reader the established standard engineering unit of capacity, and wherein the reader processor displays the established standard engineering unit of capacity on the display; and a modem in communication with the fuel gauge, wherein the modem provides a communication signal over power lines of the fuel gauge.

Abstract: A method for counting electrons from a power supply, comprising the following steps: measuring a current of a power supply forming a measured current; converting the measured current to a voltage; then into a monotonic uni-polar representation of an aggregate number of electrons having an amplitude; actuating a microprocessor in communication with a data storage just before an integrator in communication with the power supply reaches a preset limit of aggregate electrons; reading the amplitude forming a reading; transmitting the reading to an accumulator forming an accumulator value; resetting the integrator after the transmitting the reading, repeating the actuation, reading and transmission; comparing the summation of accumulator values to a calibration value; and recording the capacity when the summation of accumulator values meets or exceeds the calibration value.