Abstract: A battery control module for a battery system includes a pulse-width modulation (PWM) module that generates N PWM signals. The battery control module also includes a contactor control module that consecutively applies the N PWM signals to close a contactor in order to connect a battery to a load. Application of a first one of the N PWM signals moves the contactor at a first velocity from an open position and application of a second one of the N PWM signals moves the contactor at a second velocity to a closed position. The first velocity is less than the second velocity. N is an integer greater than one.

Abstract: A circuit that indicates an impedance of a battery dielectric includes a signal generator module that flows a first current from a ground to a first terminal of a battery. A sensor circuit generates a signal based on a second current that flows from a second terminal of the battery through a resistance to ground. The second current includes the first current and a third current that flows to ground via an impedance presented by a battery dielectric housing. A signal conversion module generates an output signal based on the signal. The output signal represents the impedance presented by the battery dielectric housing.

Abstract: There is disclosed a battery module that includes a housing. At least one terminal is melt joined with the bus member of the housing sealing the terminal relative to the bus member and providing a conductive path to an interior of the battery module. The terminal may be melt joined in an ultrasonic joining operation or in a thermal insertion operation. A plurality of cells are disposed in the housing with each of the cells electrically coupled via bus bars integrated into a bus member. Each of the cells includes a plurality of positive and negative electrodes that are spaced by a separator. The negative electrode includes a substrate having tab meeting at a flange that is connected to an active material portion of the electrode. The positive electrode includes a substrate having a tab meeting at a flange that is connected to an active material portion of the electrode.

Abstract: A battery analysis system includes a control module, a measurement module, and a pulse power module. The control module controls current to a battery to one of charge and discharge the battery. The measurement module determines N voltages across the battery at N times during a period when the control module controls the current and when the battery is at a predetermined temperature and a predetermined state of charge. N is an integer greater than 1. The pulse power module determines N resistances corresponding to the current and the N voltages across the battery and determines a pulse power value of the battery based on the N resistances. The pulse power value indicates a dynamic power of the battery to one of charge and discharge.

Abstract: A thermal imaging system for a battery module enclosure that includes first and second battery module enclosure components between which a weld is formed includes a thermal imaging camera that focuses on the first and second battery module enclosure components within a predetermined amount of time after the weld is formed and that acquires a thermal signature. A control module includes an image processing module that receives the thermal signature and that locates a predetermined reference point in the thermal signature. An image comparison module receives the thermal signature and uses the predetermined reference point to compare the thermal signature to a template signature in order to verify structural integrity of the weld. The image comparison module computes a relative measure of deviation of the thermal signature from the template signature and identifies the weld as defective when the relative measure of deviation is greater than a predetermined value.

Abstract: Disclosed herein is a modular battery system having at least one subsystem comprising a plurality of battery modules connected in series or parallel, wherein each subsystem preferably having a first endplate and a second endplate. The battery modules may be bound between the first and second endplates. A plurality of band members couple the first and second endplates to each other and bind the battery module between the endplates. Further, a data collection panel is in electrical communication with each of the battery modules and the data collection panel transmits status information of the modules to a master control module, which converts the electrical into a data transmission through a controller area network (CAN) bus. Status information may include module temperature, module pressure and module voltage, essentially any measurable parameter that may be conducted via an electrical signal. Depending on the needs of a given application, the battery modules may be connected in series or parallel.

Abstract: A battery assembly may include a battery and a battery housing. The battery may include an electrolyte vent to provide a pressurized electrolyte discharge during an electrolyte discharge event. The battery housing may contain the battery and may include an electrolyte control member to dissipate energy from and inhibit dispersion of the pressurized electrolyte discharge from the electrolyte vent during the electrolyte discharge event.

Abstract: A battery assembly may include a cooling system assembly having first and second battery modules and a coolant manifold in fluid communication therewith. The first battery module may include a first coolant flow path and the second battery module may include a second coolant flow path. The coolant manifold may include first and second ports and a main body portion to provide expansion and contraction between the first and second ports. The first port may be in communication with the first flow path and the second port may be in communication with the second flow path.

Abstract: A battery control module for a battery system includes a pulse-width modulation (PWM) module that generates N PWM signals. The battery control module also includes a contactor control module that consecutively applies the N PWM signals to close a contactor in order to connect a battery to a load. Application of a first one of the N PWM signals moves the contactor at a first velocity from an open position and application of a second one of the N PWM signals moves the contactor at a second velocity to a closed position. The first velocity is less than the second velocity. N is an integer greater than one.

Abstract: An apparatus that estimates the ohmic resistances of N batteries includes voltage and current measurement modules that respectively measure the voltage and current of each of the N batteries. An ohmic resistance estimating module over N+1 time periods receives the voltage and current measurements of each of the N batteries and receives consecutive voltage and current measurements for one of the N batteries. N is a positive integer and the ohmic resistance estimating module estimates the ohmic resistance of the battery that is associated with the consecutive voltage and current measurements.

Abstract: A battery analysis system includes a control module, a measurement module, and a pulse power module. The control module controls current to a battery to one of charge and discharge the battery. The measurement module determines N voltages across the battery at N times during a period when the control module controls the current and when the battery is at a predetermined temperature and a predetermined state of charge. N is an integer greater than 1. The pulse power module determines N resistances corresponding to the current and the N voltages across the battery and determines a pulse power value of the battery based on the N resistances. The pulse power value indicates a dynamic power of the battery to one of charge and discharge.

Abstract: A rechargeable DC power supply includes a housing including an interior, an exterior, and an integral heat sink including a heat absorbing surface formed in said interior and a heat dissipating surface formed in said exterior. The rechargeable DC power supply includes a rechargeable battery having battery terminals positioned in said interior, power supply terminals positioned at said exterior of said housing, and a first printed circuit board (PCB) assembly including a bidirectional DC-DC converter module connected between said battery terminals and said power supply terminals. The first PCB assembly is in coplanar contact with said heat absorbing surface.

Abstract: A battery assembly includes a housing and N charge storage devices within the housing. The system also includes a first tray includes a first side that includes X areas that transfer first current from electrolyte leaked from a first one of the N charge storage devices to a current detector. The tray includes a second side that insulates the housing from the electrolyte. N and X are integers greater than or equal to 1.

Abstract: A battery interface assembly for a battery system includes a first end section and a second end section. The first end section provides a source voltage from battery modules of the battery system via a conductive bus bar. The battery interface assembly also includes X intermediate housing sections that receive and house respective sections of the conductive bus bar and that detachably interconnect with each other and with the first and second end sections. The first and second end sections and the X intermediate housing sections are contiguously aligned. X is an integer greater than or equal to 0.

Abstract: A circuit that indicates an impedance of a battery dielectric includes a signal generator module that flows a first current from a ground to a first terminal of a battery. A sensor circuit generates a signal based on a second current that flows from a second terminal of the battery through a resistance to ground. The second current includes the first current and a third current that flows to ground via an impedance presented by a battery dielectric housing. A signal conversion module generates an output signal based on the signal. The output signal represents the impedance presented by the battery dielectric housing.

Abstract: A battery control module is provided for use with a battery and includes a voltage measuring module that measures battery voltage, a current measuring module that measures battery current, and a state of charge (SOC) module that communicates with said current and voltage measuring modules. In some features, the SOC module determines an unfiltered SOC of said battery, a characteristic of said unfiltered SOC, and a modified SOC that is based on said unfiltered SOC and said characteristic. In other features, the SOC module determines first and second reset voltages, compares the battery voltage to the first and second reset voltages, and determines an unfiltered SOC based on said first and second reset voltages and said battery voltage.

Abstract: A battery control module is provided for use with a battery and includes a voltage measuring module that measures battery voltage, a current measuring module that measures battery current, and a state of charge (SOC) module that communicates with the current and voltage measuring modules. The SOC module estimates an open circuit voltage based on the battery current and the battery voltage and estimates a SOC based on the open circuit voltage.

Abstract: A battery protection system is provided for a rechargeable battery. The system has a switch module that selectively interrupts battery current based on a control signal, a battery voltage sensor that senses battery voltage, a battery temperature sensor that generates a battery temperature signal, and a control module that generates said control signal based on said battery temperature signal and said battery voltage.

Abstract: A thermal imaging system for a battery module enclosure that includes first and second battery module enclosure components between which a weld is formed includes a thermal imaging camera that focuses on the first and second battery module enclosure components within a predetermined amount of time after the weld is formed and that acquires a thermal signature. A control module includes an image processing module that receives the thermal signature and that locates a predetermined reference point in the thermal signature. An image comparison module receives the thermal signature and uses the predetermined reference point to compare the thermal signature to a template signature in order to verify structural integrity of the weld. The image comparison module computes a relative measure of deviation of the thermal signature from the template signature and identifies the weld as defective when the relative measure of deviation is greater than a predetermined value.