Abstract: A fused cover assembly for a battery system. The fused cover assembly includes an attachment means configured to attach the assembly to a battery formed of a plurality interconnected cells, and a plurality of fused connections configured to make electrical contact with the interconnected cells and thereby provide a sense connection to the cells of the battery that is fused. If the sense connection to the battery cells is short-circuited, a fuse device open-circuits to protect the cell from being damaged.

Abstract: A battery pack containing a plurality of battery cells having a housing and defining an opening within the housing and a battery control module configured to be disposed within the opening of the battery pack. The battery control module may contain circuitry for controlling a connection between the battery pack and an electric load or electric source and for controlling the charging of the battery cells. The circuitry within the battery control module is connected by rigid conductors, such as conductive traces on a circuit board or bus bars rather than flexible wire cables. The battery control module may be configured to be removed for serving the battery pack without removing the battery pack housing. The battery pack may further include a battery voltage monitor configured to monitor a terminal voltage of each battery cell and send a digital signal representing the voltage to the battery control module.

Abstract: A fused cover assembly for a battery system. The fused cover assembly includes an attachment means configured to attach the assembly to a battery formed of a plurality interconnected cells, and a plurality of fused connections configured to make electrical contact with the interconnected cells and thereby provide a sense connection to the cells of the battery that is fused. If the sense connection to the battery cells is short-circuited, a fuse device open-circuits to protect the cell from being damaged.

Abstract: A power charging assembly and methods are provided to provide a pre-charge low-current state, a steady-state, high-current charging state, and an unconnect state for an electrical load of an electrical propulsion system in a hybrid electrical vehicle (HEV). The power charging assembly includes a positive contactor device, a negative contactor device, and a non-contactor device means. The rate at which that electrical load is pre-charged may be effectively controlled by using a pulse-width modulated (PWM) signal received by the non-contactor device means. A current-only carrying positive or negative contactor may be configured with the non-contactor device means to further prevent electrical arcing of the contacts of the positive and the negative contactor during power charging assembly operation.

Abstract: A power charging assembly and methods are provided to provide a pre-charge low-current state, a steady-state, high-current charging state, and an unconnect state for an electrical load of an electrical propulsion system in a hybrid electrical vehicle (HEV). The power charging assembly includes a positive contactor device, a negative contactor device, and a non-contactor device means. The rate at which that electrical load is pre-charged may be effectively controlled by using a pulse-width modulated (PWM) signal received by the non-contactor device means. A current-only carrying positive or negative contactor may be configured with the non-contactor device means to further prevent electrical arcing of the contacts of the positive and the negative contactor during power charging assembly operation.

Abstract: A method of determining the available energy of a battery provides for measuring first and second open circuit voltage of the battery with a change of energy level occurring therebetween. The two open circuit voltages are correlated to a state of charge level and the measured amount of change of energy is divided by the change of the state of charge.

Abstract: A sensor includes a detector circuit configured to measure current, voltage, and temperature of a battery. A processor is in communication with the detector circuit and is configured to convert the current, voltage, and temperature into battery information. A transmitter is in communication with the processor and is configured to wirelessly transmit the battery information. A receiver is in wireless communication with the transmitter and is configured to receive the battery information and control an external component in response to the battery information. A method includes measuring the current, voltage, and temperature of the battery, converting the current, voltage, and temperature into battery information, wirelessly transmitting the battery information to the receiver, and controlling the external component in response to the battery information.

Abstract: A method of determining the available energy of a battery provides for measuring first and second open circuit voltage of the battery with a change of energy level occurring therebetween. The two open circuit voltages are correlated to a state of charge level and the measured amount of change of energy is divided by the change of the state of charge.

Abstract: An electronic shunt resistor assembly comprises a planar shunt resistor and an electronic monitoring unit. The planar shunt resistor has a resistance element and first and second terminal bars at opposite ends of the resistance element. The electronic measuring unit has a circuit board that is supported on the planar shunt resistor and that includes input contacts for electronic components carried by the circuit board arranged along one edge of the circuit board and input/output contacts for the electronic components arranged along a opposite edge of the circuit board. A first plurality of electrical connectors connect the first terminal bar to the input contacts and a second plurality of electrical connectors connect the second terminal bar to the output contacts of the circuit board. The electrical connectors are attached to the terminal bars and the contacts solderlessly.

Abstract: A jump start protection circuit having a normally open switch and a resistor positioned in parallel intermediate to a battery and a jump start post. A controller manipulates the switch between an open position and closed position, the closed position connects the jump start post to the battery and the open position disconnects the jump start post from the battery. The controller measures voltages at the battery and jump start post and is capable of receiving one or more additional inputs. The controller closes the switch when acceptable jump start conditions are detected. The controller can open the switch or maintain the switch in an open position. The jump start circuit provides protection against attempts to charge a battery with incorrect polarity connections and attempts to charge a battery from a potentially hazardous higher voltage power source.

Abstract: A jump start protection circuit having a normally open switch and a resistor positioned in parallel intermediate to a battery and a jump start post. A controller manipulates the switch between an open position and closed position, the closed position connects the jump start post to the battery and the open position disconnects the jump start post from the battery. The controller measures voltages at the battery and jump start post and is capable of receiving one or more additional inputs. The controller closes the switch when acceptable jump start conditions are detected. The controller can open the switch or maintain the switch in an open position. The jump start circuit provides protection against attempts to charge a battery with incorrect polarity connections and attempts to charge a battery from a potentially hazardous higher voltage power source.

Abstract: A jump start protection circuit having a normally open switch and a resistor positioned in parallel intermediate to a battery and a jump start post. A controller manipulates the switch between an open position and closed position, the closed position connects the jump start post to the battery and the open position disconnects the jump start post from the battery. The controller measures voltages at the battery and jump start post and is capable of receiving one or more additional inputs. The controller closes the switch when acceptable jump start conditions are detected. The controller can open the switch or maintain the switch in an open position. The jump start circuit provides protection against attempts to charge a battery with incorrect polarity connections and attempts to charge a battery from a potentially hazardous higher voltage power source.