Abstract: Systems and methods for charging multiple rechargeable energy storage systems (“RESSs”) included in one or more vehicles using a single charging system are presented. In some embodiments, a method for charging one or more RESSs may include receiving an indication that one or more charging ports of a plurality of charging ports included in a charging system have RESSs coupled thereto. Based on the indication, a charging map may be generated. One or more charging parameters may be determined based on the generated charging map. Based on the charging parameters, a switching mechanism included in the charging system may be selectively actuated to provide electrical power from a charging power source to charging ports coupled to RESSs.

Abstract: A battery pack with a drain plug and a circuit to detect when a liquid coolant has entered the battery pack. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A strain gauge cooperative with the carrier such that a measured resistance change in the strain gauge corresponds to the soluble plug in contact with the liquid coolant. An associated circuit with the drain plug provides notification of the activation of the drain plug to the on-board computer systems.

Abstract: A method and system for power management among batteries of varying states of health. Two or more battery packs are switched on and off in square wave pulses to energize a multi-winding transformer, and the output of the transformer is used to power a load. As the state of charge of the battery packs decrease at different rates, the duty cycle of each battery pack's switch pulse is made proportional to its state of charge relative to the other battery packs. The battery pack with the greatest state of charge has the longest on-time and provides the most energy to the transformer, yet all battery packs contribute. A baseline duty cycle is computed by a proportional integral control module, based on voltage measurements at the load. Energy contribution is managed so that state of charge does not diverge even when the battery packs have widely varying states of health.

Abstract: A system and method for determining whether a resistor in a battery circuit on an electric vehicle cannot be used as a resistive heater for heating a cooling fluid for cooling the vehicle battery, but can used as a pre-charge resistor for starting the vehicle. A temperature sensor is provided proximate the resistor within the cooling fluid. The method turns on the resistor before turning on a coolant pump and samples the temperature at sample intervals over a predetermined period of time. The method then calculates an integral or differential of the sampled temperatures and compares that value with a calibrated threshold. If the temperature value is not greater than the threshold, meaning that the temperature indicates no cooling fluid is present, the algorithm disables the resistor for heating purposes, but maintains operation of the resistor for pre-charge purposes.

Abstract: Systems and methods for monitoring a state of a battery system based on information related to a measured pressure within the battery system are presented. In certain embodiments, the disclosed systems and methods may utilize a pressure-sensitive smart foam material in connection with measuring a pressure within the battery system. Based on the measured pressure information, a variety of information relating to the battery system may be determined. For example, information relating to a state of a battery system, certain events occurring within the battery system, and/or battery lifecycle information may be determined based on the measured pressure information.

Abstract: Methods and systems for balancing battery states of charge in a multi-sectioned battery. In some embodiments, states of health and states of charge of one or more sections of a multi-sectioned battery may be determined. A relationship between the states of charge and states of health of the battery sections may be determined. This information may be used apply a balancing algorithm to redistribute energy between the various battery sections in order to reduce a spread between the states of charge due to the varying states of health.

Abstract: A battery pack with a drain plug and a circuit to detect when a liquid coolant has entered the battery pack. The drain plug includes a carrier defining a cavity internal to the carrier, an inlet disposed on a first surface of the carrier and an outlet disposed on a second surface of the carrier where the first surface and the second surface fluidly displaced from one another and coupled to the cavity. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A strain gauge cooperative with the carrier such that a measured resistance change in the strain gauge corresponds to the soluble plug in contact with the liquid coolant. An associated circuit with the drain plug provides notification of the activation of the drain plug to the on-board computer systems.

Abstract: System and methods for discharging a battery system in a vehicle are presented. In certain embodiments, a battery system included in a vehicle may include a high voltage cell stack and at least one access point configured to selectively couple the high voltage cell stack with a discharging system connector associated with a discharging system. The at least one access point may include a receptacle configured to receive the discharging system connector and selectively couple the discharging system connector across the high voltage cell stack to allow for electrical energy to be discharged from the cell stack to an external discharging system.

Abstract: Systems and methods disclosed herein provide for a distributed high-voltage bus for a battery system included in a vehicle. In certain embodiments, the systems and methods disclosed herein provide for a scalable high-voltage bus architecture utilizing a common high-voltage rail for powering vehicle systems and/or modules. Independent contactors may be utilized on the opposite rail to selective power high-voltage branches. In further embodiments, a common rail pre-charge circuit may be utilized allowing for independent pre-charging of HV branches and systems and/or modules coupled to the HV bus.

Abstract: Systems and methods for switching high-voltage contactors in a battery system with reduced degradation over time are presented. In certain embodiments, a system may include solid-state switches disposed is parallel with the high-voltage contactors. The solid-state switches may be configured to selectively close when the high-voltage contactors are in transition from a closed state to an open state. By closing the solid-state switches during this transition, electrical arcing and associated degradation and/or damage to the contactors may be reduced.

Abstract: A circuit that detects if contacts in an HV contactor have been welded or stuck closed. The circuit includes a controller that generates a short duration pulse signal that closes a driver switch and allows current flow through a coil in the HV contactor. The current flow is converted to a voltage by a sensor, where the voltage is received by the controller. The controller uses the voltage, such as by comparing the voltage to a stored representative voltage of the coil current for when the HV contactor is open, to determine whether the HV contactor is closed, and possibly welded or stuck closed, or partially closed. The sensor can be the driver switch or another device, such as a resistor.

Abstract: System and methods for mitigating battery damage in a vehicle including a liquid-cooled battery system. In certain embodiments, a system for mitigating damage caused by leaks of liquid coolant in a battery system may include a one or more coolant leak sensors. A coolant leak detection system communicatively coupled to the coolant leak sensors may be configured to detect an occurrence of a liquid coolant leak in the battery system based on information provided by the coolant leak sensors. One or more valves communicatively coupled with the coolant leak detection system may actuate by the coolant leak detection system when a leak of liquid coolant is detected, thereby allowing leaked liquid coolant to drain from the battery system.

Abstract: Systems and methods for charging multiple rechargeable energy storage systems (“RESSs”) included in one or more vehicles using a single charging system are presented. In some embodiments, a method for charging one or more RESSs may include receiving an indication that one or more charging ports of a plurality of charging ports included in a charging system have RESSs coupled thereto. Based on the indication, a charging map may be generated. One or more charging parameters may be determined based on the generated charging map. Based on the charging parameters, a switching mechanism included in the charging system may be selectively actuated to provide electrical power from a charging power source to charging ports coupled to RESSs.

Abstract: A high-voltage relay system for a vehicle. The system includes a high-voltage bus, a parallel relay set and a controller. The parallel relay set includes two or more relays wired in parallel and that are electrically coupled to the high-voltage bus. The controller is programmed to adjust the power flowing through the parallel relay set when a malfunction is detected in one of the relays in the set. The system can include a high-voltage power source electrically coupled to the high voltage bus through the parallel relay set, where the controller reduces the power flowing through the parallel relay by reducing output of the high-voltage power source. The system can include a high-voltage motor electrically coupled to the high voltage bus through the parallel relay set, where the controller reduces the power flowing through the parallel relay set by reducing the motor's power demands.

Abstract: Methods and systems for balancing battery states of charge in a multi-sectioned battery. In some embodiments, states of health and states of charge of one or more sections of a multi-sectioned battery may be determined. A relationship between the states of charge and states of health of the battery sections may be determined. This information may be used apply a balancing algorithm to redistribute energy between the various battery sections in order to reduce a spread between the states of charge due to the varying states of health.

Abstract: A battery pack with a drain plug. The drain plug includes a carrier defining a cavity internal to the carrier, an inlet disposed on a first surface of the carrier and an outlet disposed on a second surface of the carrier where the first surface and the second surface fluidly displaced from one another and coupled to the cavity. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A first lead and a second lead are configured to signally connect an impedance element that is cooperative with the carrier, to a circuit such that when the continuity of the circuit is interrupted, the circuit provides notification of the activation of the drain plug to the on-board computer systems.

Abstract: System and methods for discharging a battery system in a vehicle are presented. In certain embodiments, a battery system included in a vehicle may include a high voltage cell stack and at least one access point configured to selectively couple the high voltage cell stack with a discharging system connector associated with a discharging system. The at least one access point may include a receptacle configured to receive the discharging system connector and selectively couple the discharging system connector across the high voltage cell stack to allow for electrical energy to be discharged from the cell stack to an external discharging system.

Abstract: A device and method for operating automotive battery system relays and related switches. By creating a dual bipolar magnetic field adjacent the contactor portion of a switching mechanism in the relay, the magnetic field used to promote arc extinguishing is shifted, which in turn reduces the Lorentz force that forms as a byproduct of the field. Such a configuration has the potential for simultaneously maintaining arc-extinguishing capability and improving short-circuit withstanding capability while reducing the tendency of the Lorentz forces to interfere with the operation of a solenoid or other switch-activating mechanisms. Such devices and methods may be used in conjunction with hybrid-powered and electric-powered vehicles.

Abstract: System and methods for mitigating battery damage in a vehicle including a liquid-cooled battery system. In certain embodiments, a system for mitigating damage caused by leaks of liquid coolant in a battery system may include a one or more coolant leak sensors. A coolant leak detection system communicatively coupled to the coolant leak sensors may be configured to detect an occurrence of a liquid coolant leak in the battery system based on information provided by the coolant leak sensors. One or more valves communicatively coupled with the coolant leak detection system may actuate by the coolant leak detection system when a leak of liquid coolant is detected, thereby allowing leaked liquid coolant to drain from the battery system.

Abstract: A circuit for discharging a battery including a voltage divider network having a plurality of resistors and being electrically coupled in parallel with the battery, where the voltage divider network divides a voltage potential of the battery and where a voltage potential across one of the resistors in the voltage divider network provides a reference voltage. The circuit also includes a load electrically coupled in parallel with the battery and the voltage divider network and a switch electrically coupled in series with the load and being controlled by the reference voltage. A current flow through the load generated by the battery discharges the battery which causes the reference voltage to decrease until the reference voltage falls to a predetermined voltage that causes the switch to open so that the battery is discharged to the predetermined voltage. The switch can be a soft-switch or a hard-switch.