Abstract: A method is provided for controlling a vehicle battery system that includes a voltage bus having positive and negative bus rails, at least one battery pack connected to the voltage bus and having positive and negative battery terminals, and a battery disconnect unit. The method includes disconnecting the at least one battery pack from the voltage bus via the battery disconnect unit by performing a first battery disconnect process upon detecting an event condition, by performing a second battery disconnect process upon detecting a high overcurrent condition, and by performing a third battery disconnect process upon detecting a low overcurrent condition. The first battery disconnect process utilizes opening a main pyro fuse, the second battery disconnect process utilizes one or more of thermal fuses, solid-state relays and/or current sensors, and the third battery disconnect process utilizes one or more contactors or solid-state relays.

Abstract: A battery electric system for a motor vehicle or another electrified system includes a battery pack connected to a direct current voltage bus, and having positive and negative battery terminals, a main pyrotechnic fuse (“pyro fuse”), a high-voltage (HV) component connected to the bus via an HV channel, a current sensing element connected to the HV component on the HV channel, and a control system configured to selectively disconnect the battery pack from the bus by transmitting a voltage signal to the main pyro fuse when a measured current value from the current sensor is indicative of a short-circuit fault. A channel switch may be connected to or integral with the current sensing element, and configured to disconnect the HV component from the bus by opening in response to the measured current value.

Abstract: A cooling system for a rechargeable energy system includes a plurality of bus bars, a cooling plate configured for cooling the plurality of bus bars and disposed in a thermally-conductive relationship with a portion of each of the plurality of bus bars, and an isolation component disposed between and in contact with the cooling plate and each of the plurality of bus bars. A rechargeable energy storage system and device are also described.

Abstract: An electrical system includes a battery disconnect unit (BDU) connected to a rechargeable energy storage system (RESS) via a high-voltage bus. The BDU has one or more contactors that close responsive a low-voltage drive current to thereby connect the RESS to the high-voltage bus. A low-voltage drive circuit conducts the drive current to the contactor(s). Opening of a low-voltage connection interrupts the drive current and causes the contactor(s) to transition from the closed state to an open state. The contactor(s) open in response to interruption of the drive current to thereby disconnect the RESS. The contactor(s) may be closed again after a lockout safety procedure, such that reestablishing the electrical connection does not itself re-energize the high-voltage bus. An electrified powertrain includes a transmission, electric machine, power inverter module, and the above-noted electrical system.

Abstract: A cooling system for a rechargeable energy system includes a plurality of bus bars, a cooling plate configured for cooling the plurality of bus bars and disposed in a thermally-conductive relationship with a portion of each of the plurality of bus bars, and an isolation component disposed between and in contact with the cooling plate and each of the plurality of bus bars. A rechargeable energy storage system and device are also described.

Abstract: An apparatus for flexible DC fast charging of an electrified vehicle includes a charge receptacle and a vehicle charging controller programmed to establish a wireless communication with a charging station. The apparatus further includes a reconfigurable energy storage system selectively and electrically connected to the charge receptacle. The reconfigurable energy storage system includes a first rechargeable energy storage device selectively and electrically connected to the charge receptacle, a second rechargeable energy storage device selectively connected to the charge receptacle, and a plurality of low-loss switching devices selectively connected to the first rechargeable energy storage device and the second rechargeable energy storage device.

Abstract: An electrical system includes a battery disconnect unit (BDU) connected to a rechargeable energy storage system (RESS) via a high-voltage bus. The BDU has one or more contactors that close responsive a low-voltage drive current to thereby connect the RESS to the high-voltage bus. A low-voltage drive circuit conducts the drive current to the contactor(s). Opening of a low-voltage connection interrupts the drive current and causes the contactor(s) to transition from the closed state to an open state. The contactor(s) open in response to interruption of the drive current to thereby disconnect the RESS. The contactor(s) may be closed again after a lockout safety procedure, such that reestablishing the electrical connection does not itself re-energize the high-voltage bus. An electrified powertrain includes a transmission, electric machine, power inverter module, and the above-noted electrical system.

Abstract: An apparatus for flexible DC fast charging of an electrified vehicle includes a charge receptacle and a vehicle charging controller programmed to establish a wireless communication with a charging station. The apparatus further includes a reconfigurable energy storage system selectively and electrically connected to the charge receptacle. The reconfigurable energy storage system includes a first rechargeable energy storage device selectively and electrically connected to the charge receptacle, a second rechargeable energy storage device selectively connected to the charge receptacle, and a plurality of low-loss switching devices selectively connected to the first rechargeable energy storage device and the second rechargeable energy storage device.

Abstract: An apparatus for flexible DC fast charging of an electrified vehicle includes a charge receptacle and a vehicle charging controller programmed to establish a wireless communication with a charging station. The apparatus further includes a reconfigurable energy storage system selectively and electrically connected to the charge receptacle. The reconfigurable energy storage system includes a first rechargeable energy storage device selectively and electrically connected to the charge receptacle, a second rechargeable energy storage device selectively connected to the charge receptacle, and a plurality of low-loss switching devices selectively connected to the first rechargeable energy storage device and the second rechargeable energy storage device.

Abstract: An apparatus for flexible DC fast charging of an electrified vehicle includes a charge receptacle and a vehicle charging controller programmed to establish a wireless communication with a charging station. The apparatus further includes a reconfigurable energy storage system selectively and electrically connected to the charge receptacle. The reconfigurable energy storage system includes a first rechargeable energy storage device selectively and electrically connected to the charge receptacle, a second rechargeable energy storage device selectively connected to the charge receptacle, and a plurality of low-loss switching devices selectively connected to the first rechargeable energy storage device and the second rechargeable energy storage device.

Abstract: Disclosed herein are systems and methods for control of a current interruption component in a battery system. Various embodiments consistent with the present disclosure may include a detection system configured to detect an event (e.g., an impact event, a resistive short, a coolant leak, etc.) and a control system configured to receive information from the detection system and to generate a control signal based upon detection of the event. The control signal may selectively actuate an electrical clearing component. A current interruption component may be configured to selectively interrupt a flow of current upon an occurrence of a condition that results from actuation of the electrical clearing component. Upon detection of the event by the detection system, the control system may generate the control signal to actuate the electrical clearing component, and the actuation of the electrical clearing component may trigger the current interruption system.

Abstract: System and methods for detecting electrical leakages in a battery sensing are presented. In certain embodiments, the systems and methods allow a vehicle battery sensing circuit and/or other associated system to detect certain electrical leakages and implement one or more actions to protect vehicle systems from damage resulting from such leakages.

Abstract: System and methods for measuring parameters of a battery system using a battery sensing circuit are presented. In certain embodiments, the systems and methods allow a vehicle battery sensing circuit and/or other associated system to measure a compensation parameter. The compensation parameter may be utilized by the battery sensing circuit and/or other associated system in measuring other parameters relating to the battery system including cell voltages.

Abstract: System and methods for measuring parameters of a battery system using a battery sensing circuit are presented. In certain embodiments, the systems and methods allow a vehicle battery sensing circuit and/or other associated system to measure a compensation parameter. The compensation parameter may be utilized by the battery sensing circuit and/or other associated system in measuring other parameters relating to the battery system including cell voltages.

Abstract: System and methods for detecting electrical leakages in a battery sensing are presented. In certain embodiments, the systems and methods allow a vehicle battery sensing circuit and/or other associated system to detect certain electrical leakages and implement one or more actions to protect vehicle systems from damage resulting from such leakages.

Abstract: Disclosed herein are systems and methods for control of a current interruption component in a battery system. Various embodiments consistent with the present disclosure may include a detection system configured to detect an event (e.g., an impact event, a resistive short, a coolant leak, etc.) and a control system configured to receive information from the detection system and to generate a control signal based upon detection of the event. The control signal may selectively actuate an electrical clearing component. A current interruption component may be configured to selectively interrupt a flow of current upon an occurrence of a condition that results from actuation of the electrical clearing component. Upon detection of the event by the detection system, the control system may generate the control signal to actuate the electrical clearing component, and the actuation of the electrical clearing component may trigger the current interruption system.

Abstract: A sensor arrangement and method that may be used with a variety of different energy storage devices, including battery packs found in hybrid vehicles, battery electric vehicles, and other types of vehicles. An exemplary sensor arrangement includes a number of sensor units, a controller, and several connections, wherein two or more sensor units are coupled to each node of the battery pack and are coupled to the controller over different connections. An exemplary method is divided into two aspects: an error detection aspect and an error resolution aspect. Because the sensor arrangement provides multiple sensor readings for each node being evaluated, the method can enable the sensor arrangement to continue operating accurately and with redundancy even if it experiences a loss of one or more sensor units.

Abstract: A sensor arrangement and method that may be used with a variety of different energy storage devices, including battery packs found in hybrid vehicles, battery electric vehicles, and other types of vehicles. Some battery monitoring systems, such as those designed to monitor and/or control lithium-ion battery packs, may require individual voltage readings for each and every cell. If a battery monitoring system component—even one that provides just one of these sensor readings—malfunctions or otherwise experiences a fault condition, then it may be necessary to bring the entire vehicle in for service. The exemplary sensor arrangement and method may be used to control a series of balancing switches in the sensor arrangement in such a way that enables the vehicle to detect fault conditions and to continue operating successfully in the event that such fault conditions occur.

Abstract: A sensor arrangement and method that may be used with a variety of different energy storage devices, including battery packs found in hybrid vehicles, battery electric vehicles, and other types of vehicles. An exemplary sensor arrangement includes a number of sensor units, a controller, and several connections, wherein two or more sensor units are coupled to each node of the battery pack and are coupled to the controller over different connections. An exemplary method is divided into two aspects: an error detection aspect and an error resolution aspect. Because the sensor arrangement provides multiple sensor readings for each node being evaluated, the method can enable the sensor arrangement to continue operating accurately and with redundancy even if it experiences a loss of one or more sensor units.

Abstract: A sensor arrangement and method that may be used with a variety of different energy storage devices, including battery packs found in hybrid vehicles, battery electric vehicles, and other types of vehicles. Some battery monitoring systems, such as those designed to monitor and/or control lithium-ion battery packs, may require individual voltage readings for each and every cell. If a battery monitoring system component—even one that provides just one of these sensor readings—malfunctions or otherwise experiences a fault condition, then it may be necessary to bring the entire vehicle in for service. The exemplary sensor arrangement and method may be used to control a series of balancing switches in the sensor arrangement in such a way that enables the vehicle to detect fault conditions and to continue operating successfully in the event that such fault conditions occur.