Abstract: A method for adapting a usage level of a battery pack includes measuring cell sense data for each respective battery cell using a cell sense circuit, the cell sense data including a cell voltage, current, and temperature. The method includes processing the cell sense data, for each respective battery cell, through multiple battery state functions of a controller to generate numeric cell degradation values (CDVs). The battery state functions are calibrated relationships of the cell sense data to predetermined battery fault conditions. Thereafter, the method includes automatically adapting the usage level of the battery pack during operation of the battery pack, via the controller, based on the numeric CDVs. An electric powertrain system includes the battery pack, cell sense circuit, a rotary electric machine, and a controller configured to execute the above method.

Abstract: A panel system includes a chassis holding one or more tray arrangements, which are each configured to receive one or more cassettes at two or more bays. The tray arrangements and cassettes cooperate to define a cassette sensor arrangement and a port occupancy sensor arrangement having separate interface points. The cassette sensor arrangement may include electronic memory storing physical layer information about the cassette. All active components of the port occupancy sensor arrangement are disposed on the tray while the electronic memories of the cassette sensor arrangement are stored on the cassettes.

Abstract: A method for adapting a usage level of a battery pack includes measuring cell sense data for each respective battery cell using a cell sense circuit, the cell sense data including a cell voltage, current, and temperature. The method includes processing the cell sense data, for each respective battery cell, through multiple battery state functions of a controller to generate numeric cell degradation values (CDVs). The battery state functions are calibrated relationships of the cell sense data to predetermined battery fault conditions. Thereafter, the method includes automatically adapting the usage level of the battery pack during operation of the battery pack, via the controller, based on the numeric CDVs. An electric powertrain system includes the battery pack, cell sense circuit, a rotary electric machine, and a controller configured to execute the above method.

Abstract: System and method of controlling operation of a device having multiple rechargeable packs configured to store energy. The multiple rechargeable packs include at least one primary pack characterized by a first capacity and at least one auxiliary pack characterized by a second capacity, the first capacity being greater than the second capacity. A controller is configured to selectively command one or more of the multiple rechargeable packs to begin at least one of discharging and charging. When an estimated end of trip time is less than or equal to a discharging time of the at least one auxiliary pack, the discharging of the at least one auxiliary pack is begun. When the estimated end of trip time is greater than the discharging time, the discharging is delayed until the respective state of charge of the at least one primary pack reaches a first threshold.

Abstract: System and method of controlling operation of a device having multiple rechargeable packs configured to store energy. The multiple rechargeable packs include at least one primary pack characterized by a first capacity and at least one auxiliary pack characterized by a second capacity, the first capacity being greater than the second capacity. A controller is configured to selectively command one or more of the multiple rechargeable packs to begin at least one of discharging and charging. When an estimated end of trip time is less than or equal to a discharging time of the at least one auxiliary pack, the discharging of the at least one auxiliary pack is begun. When the estimated end of trip time is greater than the discharging time, the discharging is delayed until the respective state of charge of the at least one primary pack reaches a first threshold.

Abstract: A method and system are disclosed for estimating cell voltage excursion in a battery pack in the presence of a sensing fault in which actual cell voltages of first and second battery cells in a block of battery cells become unknown or missing. The sensing fault is detected, and a cell voltage is determined for each cell in the block other than the first and second cells. The method also includes measuring a block voltage, calculating an average cell voltage in the block, and estimating that the first cell is equal to the calculated average cell voltage. All excursion or deviation of the measured block voltage from a sum of the cell voltages and the estimated cell voltage of the first cell is assigned to the second cell. A control action is executed using the estimated cell voltages, including selectively enabling or disabling functionality of the battery pack.

Abstract: A method and system are disclosed for estimating cell voltage excursion in a battery pack in the presence of a sensing fault in which actual cell voltages of first and second battery cells in a block of battery cells become unknown or missing. The sensing fault is detected, and a cell voltage is determined for each cell in the block other than the first and second cells. The method also includes measuring a block voltage, calculating an average cell voltage in the block, and estimating that the first cell is equal to the calculated average cell voltage. All excursion or deviation of the measured block voltage from a sum of the cell voltages and the estimated cell voltage of the first cell is assigned to the second cell. A control action is executed using the estimated cell voltages, including selectively enabling or disabling functionality of the battery pack.

Abstract: Methods, apparatus and systems are provided for determining a characteristic of an energy source. One exemplary method involves obtaining a measured current associated with the energy source using a current sensor and obtaining a measured voltage associated with the energy source. In response to identifying an absence of an anomalous condition of the current sensor based on the measured current, the method determines a current-compensated value for the characteristic based at least in part on the measured voltage and the measured current. In response to identifying the anomalous condition of the current sensor based on the measured current, the method determines an uncompensated value for the characteristic based at least in part on the measured voltage.

Abstract: A method and system for accurately estimating one or more vehicle battery parameters, such as state-of-charge (SOC). In an exemplary embodiment, a battery control module gathers standard battery readings for estimating SOC at a relatively slow sampling rate. The battery control module receives adjustment data from one or more control modules located around the vehicle, where the control modules gather readings at faster sampling rates and then provide the information to the slower battery control module. The adjustment data from the faster control modules is representative of energy consumption and/or generation events that occur in between the readings taken by the battery control module at the slower sampling rate, and enable the method to make a more accurate and complete estimate of SOC.

Abstract: A method for operating a hybrid vehicle, particularly one that includes both a primary and an auxiliary power source. According to one exemplary embodiment, the method seeks to decouple or disassociate a driver's engagement of an accelerator pedal with activation of an auxiliary power source, such as an internal combustion engine. This way, if the driver aggressively engages the accelerator pedal while the hybrid vehicle is being propelled by a battery and an electrical motor, the method will delay activation of the internal combustion engine so that the two events do not appear to be linked or connected to one another. Delaying activation of the internal combustion engine while the electric motor is under a heavy stress load may also improve the drive quality of the hybrid vehicle.

Abstract: A method and system for manipulating, adjusting or otherwise controlling a state-of-charge (SOC) operating range for a high voltage vehicle battery, such as the type used for hybrid or electric vehicle propulsion. By providing a dynamic SOC operating range that changes in response to changing battery conditions, the battery performance may be improved so that the battery life is extended. Depending on the particular embodiment, the dynamic SOC operating range may have different combinations of hard and/or soft boundaries or limits.

Abstract: System and methods for balancing a vehicle battery system are presented. In certain embodiments, a method for balancing a vehicle battery system including a plurality of sections may include calculating a plurality of quanta of energy required for each of the plurality of sections to reaching a balancing point. Based at least in part on the calculated plural of quanta of energy, it may be determined that the plurality of sections of the battery system are unbalanced. To balance the battery system, a balancing system may be selectively actuated to change the amounts of energy stored in one or more of the plurality of cells such that the plurality of quanta of energy are within a particular range.

Abstract: A method for estimating the voltage of a battery element of a vehicle battery system is provided. The method comprises providing a balancing/sensing circuit having a series combination of a balancing switch and a balancing resistive element electrically connected in parallel with the battery element, and measuring the voltage across the combination of the balancing switch and balancing resistive element when the balancing switch is presumed to be in a “closed” state. The method further comprises deriving a compensated value for the measured voltage using empirically-derived data, wherein the compensated value compensates for a voltage drop occurring in the balancing/sensing circuit when the balancing switch is in the “closed” state and represents an estimate of the voltage of the battery element. A battery system is also provided that includes a battery element, a balancing/sensing circuit, a sensor, and a control module configured to perform the method described above.

Abstract: A system and method is provided for estimating the capacity of a battery element in a vehicle, such as a hybrid electric vehicle. In one embodiment, the method determines if one or more threshold conditions have been met (e.g., conditions pertaining to battery temperature or battery state-of-charge (SOC)) and calculates the internal resistance of the battery element. When the threshold conditions have been met, the method uses the calculated internal resistance to estimate the capacity of the battery element. A corresponding battery system is also provided that includes a battery element, one or more battery sensors, and a control module configured to perform the method described above.

Abstract: A method and system for use with a vehicle battery pack having a number of individual battery cells, where the method estimates, extrapolates or otherwise determines individual cell resistances. According to an exemplary embodiment, the method and system use a voltage and temperature reading for each of the individual battery cells, as well as a voltage and current reading for the overall battery pack to determine one or more cell resistance values, such as a minimum and maximum cell resistance for the battery pack. This approach relies upon temperature deviations in the battery pack to make assumptions or estimates regarding individual battery cell resistances. By having individual cell resistance values—instead of using an overall pack resistance value and building in a buffer to account for cell variations—better and more accurate cell-level data can be obtained that, in turn, can improve charging, discharging, cell balancing and/or other battery-related processes.

Abstract: Methods, apparatus and systems are provided for determining a characteristic of an energy source. One exemplary method involves obtaining a measured current associated with the energy source using a current sensor and obtaining a measured voltage associated with the energy source. In response to identifying an absence of an anomalous condition of the current sensor based on the measured current, the method determines a current-compensated value for the characteristic based at least in part on the measured voltage and the measured current. In response to identifying the anomalous condition of the current sensor based on the measured current, the method determines an uncompensated value for the characteristic based at least in part on the measured voltage.

Abstract: Methods and systems are provided that determine a voltage of a cell of a battery pack of a vehicle. A sensor is configured to measure a preliminary value of the voltage of the cell while the battery pack is being balanced. A processor is coupled to the sensor, and is configured to determine an offset from balancing of the battery pack, and calculate an adjusted value of the voltage of the cell using the preliminary value and the offset.

Abstract: System and methods for balancing a vehicle battery system are presented. In certain embodiments, a method for balancing a vehicle battery system including a plurality of sections may include calculating a plurality of quanta of energy required for each of the plurality of sections to reaching a balancing point. Based at least in part on the calculated plural of quanta of energy, it may be determined that the plurality of sections of the battery system are unbalanced. To balance the battery system, a balancing system may be selectively actuated to change the amounts of energy stored in one or more of the plurality of cells such that the plurality of quanta of energy are within a particular range.

Abstract: A method for estimating the voltage of a battery element of a vehicle battery system is provided. The method comprises providing a balancing/sensing circuit having a series combination of a balancing switch and a balancing resistive element electrically connected in parallel with the battery element, and measuring the voltage across the combination of the balancing switch and balancing resistive element when the balancing switch is presumed to be in a “closed” state. The method further comprises deriving a compensated value for the measured voltage using empirically-derived data, wherein the compensated value compensates for a voltage drop occurring in the balancing/sensing circuit when the balancing switch is in the “closed” state and represents an estimate of the voltage of the battery element. A battery system is also provided that includes a battery element, a balancing/sensing circuit, a sensor, and a control module configured to perform the method described above.

Abstract: A vehicle battery and charging method that may be used to balance cell voltages during a battery charging operation, and may do so in a way that protects the individual cells from over-charging and improves the overall efficiency of the operation. According to one example, the vehicle battery includes a number of cell-balancing current paths, each of which is connected in parallel to an individual battery cell and can shunt or bypass the corresponding cell when its voltage exceeds some maximum amount. This may enable under-charged battery cells to be charged at the same time that over-charged battery cells are bypassed. Each of the cell-balancing current paths may include a series-connected electronic switch and zener diode combination, where the electronic switch is controlled by a battery control module so that cell-balancing can be enabled during a battery charging operation and disabled at other times.