Abstract: The methods in this disclosure allow for the identification, selection, and arrangement of cells, blocks, and modules in large scale battery systems, such as electric vehicle battery systems. An example embodiment of the present invention allows for the identification of the cells, blocks, and modules with a unique identifier or associated parameter (e.g., internal resistance contributions or capacity). Additionally, to form a block, cells may be selected from a group of capacity-range sorting bins. Based on a parameter of the cell, a pseudo-number generator may be also be used to select cells from an available inventory of cells as maintained in a cell database based. Cells may also be placed in a block for uniform effective cell impedance and even cell aging while minimizing overall block capacity degradation caused by cycling. Block capacities may also be computed based on a known average temperature gradient during operation.

Abstract: A circuit for balancing battery cells includes a plurality of resistors configured in parallel with the battery cells, and a plurality of switches configured in series with the resistors. A control circuit causes the switches to balance the battery cells based on detected voltage of the battery cells and based on past operation of the cells.

Abstract: The methods in this disclosure allow for the identification, selection, and arrangement of cells, blocks, and modules in large scale battery systems, such as electric vehicle battery systems. An example embodiment of the present invention allows for the identification of the cells, blocks, and modules with a unique identifier or associated parameter (e.g., internal resistance contributions or capacity). Additionally, to form a block, cells may be selected from a group of capacity-range sorting bins. Based on a parameter of the cell, a pseudo-number generator may be also be used to select cells from an available inventory of cells as maintained in a cell database based. Cells may also be placed in a block for uniform effective cell impedance and even cell aging while minimizing overall block capacity degradation caused by cycling. Block capacities may also be computed based on a known average temperature gradient during operation.

Abstract: A battery system monitors the status of a battery and ensures safe conditions under a range of events adversely affecting the safety of the battery cells, the battery pack or enclosure, or a vehicle housing the battery. In response to the safety event, the battery system provides one or more responses to secure the battery, disconnect the battery, extinguish a fire, or maintain a safe temperature. Upon detecting the safety event, the a controller activates the safety device accordingly to ensure safe conditions.

Abstract: A battery system employs a plurality of PTC devices and an additional temperature sensor to provide safety and optimization features in a multi-cell battery system. The system provides both temperature fault detection and information that may be used for battery system performance optimization. A single negative temperature coefficient (NTC) thermistor and multiple PTC thermal protection devices are integrated into a battery block, and can be implemented as a single sensor package that is in thermal contact with each of the battery cells in the battery block.

Abstract: The methods in this disclosure allow for the identification, selection, and arrangement of cells, blocks, and modules in large scale battery systems, such as electric vehicle battery systems. An example embodiment of the present invention allows for the identification of the cells, blocks, and modules with a unique identifier or associated parameter (e.g., internal resistance contributions or capacity). Additionally, to form a block, cells may be selected from a group of capacity-range sorting bins. Based on a parameter of the cell, a pseudo-number generator may be also be used to select cells from an available inventory of cells as maintained in a cell database based. Cells may also be placed in a block for uniform effective cell impedance and even cell aging while minimizing overall block capacity degradation caused by cycling. Block capacities may also be computed based on a known average temperature gradient during operation.

Abstract: An electric vehicle power system including a battery system, a bus configured to transfer power to a motor drive, and a control circuit to selectively couple the battery to the bus. The control circuit is discharges capacitance of the bus to a chassis in response to a disconnect between the battery and the bus. Further, the control circuit measures impedance across the bus. As a result, the control circuit can monitor integrity of the bus and detect a fault, such as a short circuit or degraded bus insulation.

Abstract: A large battery array, particularly for use in an electric vehicle, is formed of multiple modules, each containing plural battery cells and module management electronics. Each battery module has a nominal output voltage in the range of about 5 volts to about 17 volts. A controller communicates with individual battery modules in the array and controls switching to connect the modules in drive and charging configurations. The module management electronics monitor conditions of each battery module, including the cells it contains, and communicates these conditions to the controller. The module management electronics may place the modules in protective modes based upon the performance of each module in comparison to known or configurable specifications. The modules may be pluggable devices so that each module may be replaced if the module is in a permanent shutdown protective mode or if a non-optimal serviceable fault is detected.