Abstract: A battery pack system module may include a module bypass switch for allowing charge current to bypass the battery pack system module. The module bypass switch may be activated to divert charging current from the battery pack system module to other battery pack system modules. The charging current may be diverted to bring other battery pack system modules into balance with the battery pack system module. That is, to bring the state of charge of all battery pack system modules into coarse balance. When the module bypass switch is activated, charging current through the module bypass switch may be monitored by a current sensing device such as a current sensing resistor. A microprocessor may receive information about the bypass current level and use the information to determine when to de-activate the module bypass switch. Sensing current through a module bypass switch allows more accurate and quicker inter-module balancing.

Abstract: Internal shorts and other failures in lithium-ion battery cells may be detected during balancing of the battery cells. A counter may be used to detect when a battery cell is behaving differently than other battery cells by balancing more or less frequently. The counter may increment each time a battery cell is balanced to the other battery cells. A misbehaving battery cell may be flagged, when the counter exceeds a threshold value, for safety checks before an overheating event occurs. This misbehaving battery cell may be faulty due to an internal short. If the faulty battery cell is not corrected by replacement with a different battery cell or corrected by a user resetting the counter, the misbehaving battery cell may be disconnected to prevent the overheating event.

Abstract: A battery pack system module may include a module bypass switch for allowing charge current to bypass the battery pack system module. A charge switch and a discharge switch may be coupled with the module bypass switch. When other battery pack system modules are coupled in series with the module, balancing between modules may be achieved by allowing charge current to bypass the unbalanced modules and charge other modules. For example, when an unbalanced module is at a higher level of charge than other modules, a charge switch and a discharge switch in the unbalanced module de-activate and a module bypass switch activates to allow charge current to rapidly bring other modules into balance. The discharge switch and the charge switch allow the charging current to bypass the unbalanced module creating little or no additional heat dissipation.

Abstract: Battery cells may be monitored and a historical profile of the battery generated. The historical profile may be used to analyze a state-of-health of the battery cell. For example, the historical profile may be used to determine when a battery cell has developed an internal short that creates a safety hazard. The historical profile may include a count of the number of times the battery cell was out of balance and a count of the number of Coulombs the battery cell was out of balance. The number of Coulombs may be counted for a window of time. When the number of Coulombs exceeds a Coulomb threshold, a state-of-health flag may be set for the battery cell. The Coulomb threshold may be adjusted based, in part, on the counted number of times the battery cell is out of balance.

Abstract: Internal shorts and other failures in lithium-ion battery cells may be detected during balancing of the battery cells. A counter may be used to detect when a battery cell is behaving differently than other battery cells by balancing more or less frequently. The counter may increment each time a battery cell is balanced to the other battery cells. A misbehaving battery cell may be flagged, when the counter exceeds a threshold value, for safety checks before an overheating event occurs. This misbehaving battery cell may be faulty due to an internal short. If the faulty battery cell is not corrected by replacement with a different battery cell or corrected by a user resetting the counter, the misbehaving battery cell may be disconnected to prevent the overheating event.

Abstract: A battery pack system module may include a module bypass switch for allowing charge current to bypass the battery pack system module. The module bypass switch may be activated to divert charging current from the battery pack system module to other battery pack system modules. The charging current may be diverted to bring other battery pack system modules into balance with the battery pack system module. That is, to bring the state of charge of all battery pack system modules into coarse balance. When the module bypass switch is activated, charging current through the module bypass switch may be monitored by a current sensing device such as a current sensing resistor. A microprocessor may receive information about the bypass current level and use the information to determine when to de-activate the module bypass switch. Sensing current through a module bypass switch allows more accurate and quicker inter-module balancing.

Abstract: The remaining capacity of a power source, such as a battery, may be monitored with a microprocessor by integrating data received from a current sensor. The microprocessor may measure electrons passing through the battery by sampling the integrator and summing the values recorded from the integrator. Each time the integrator is sampled, the microprocessor may reset the integrator to prevent the integrator from saturating. The microprocessor may sample the integrator when the integrator approaches a predetermined value. The remaining capacity of the battery may be calculated based on calibration values and the sum of electrons measured by the integrator. The remaining capacity may be communicated to remote users through a network and displayed in an executive dashboard.

Abstract: A battery pack system module may include a module bypass switch for allowing charge current to bypass the battery pack system module. A charge switch and a discharge switch may be coupled with the module bypass switch. When other battery pack system modules are coupled in series with the module, balancing between modules may be achieved by allowing charge current to bypass the unbalanced modules and charge other modules. For example, when an unbalanced module is at a higher level of charge than other modules, a charge switch and a discharge switch in the unbalanced module de-activate and a module bypass switch activates to allow charge current to rapidly bring other modules into balance. The discharge switch and the charge switch allow the charging current to bypass the unbalanced module creating little or no additional heat dissipation.

Abstract: The remaining capacity of a battery may be monitored with a microprocessor by integrating a voltage measured across a current sense resistor coupled in series with the battery. The microprocessor may measure electrons passing through the battery by sampling the integrator and summing the values recorded from the integrator. Each time the integrator is sampled, the microprocessor may reset the integrator to prevent the integrator from saturating. The remaining capacity of the battery may be calculated based on calibration values and the sum of electrons measured by the integrator. The remaining capacity may be communicating to remote users through a network and displayed in an executive dashboard.