Abstract: A method for monitoring a battery module in a vehicle includes selecting an upper cut-off voltage and a lower cut-off voltage for the battery module. The method includes charging the battery cell from an original state to a first benchmark voltage greater than an upper cut-off voltage, via a first charging process. The method includes discharging the battery cell from the first benchmark voltage to a second benchmark voltage less than a lower cut-off voltage, via a first discharging process. The battery module is then charged from the second benchmark voltage to the first benchmark voltage, via a second charging process. The method includes obtaining a ratio of a discharging capacity to a charging capacity of the battery module. Operation of the vehicle is controlled based in part on the ratio, including taking at least one remedial action if the ratio is less than a predefined threshold.

Abstract: A system for key absence management in a vehicle configured to be started by an electronic key fob includes a key absence management controller that implements a method configured to authorize starting of the vehicle by monitoring presence and absence of the electronic key fob in the vehicle. If the controller finds the electronic key fob to be present in the vehicle, then the controller authorizes starting of the vehicle. If the controller finds the electronic key fob to be absent from the vehicle, then the controller authorizes starting of the vehicle based on detection of a keyless authority indicator. A vehicle configured to be started by an electronic key fob includes the system with the controller that implements the method.

Abstract: A vehicle includes a propulsion system having multiple electric motors. A battery system is connected to the electric motors via a direct current to direct current (DC-DC) converter and an inverter. The battery system includes a battery assembly having a plurality of battery modules. Each of the battery modules has multiple individual battery cells arranged in battery packs, a set of sensors configured to monitor a set of parameters of each battery pack, and a plurality of battery pack mounts. Each battery pack mount includes a base plate and a top plate and an actuator configured to alter a distance between plates. A monitoring unit is configured to monitor a value representative of a battery pack pressure, determine whether the value falls within a pressure threshold window, and maintain the value within the pressure threshold window by actively altering the battery pack pressure.

Abstract: An electrical system includes a high-voltage battery pack assembly having a first cell set with a first group of energy storage cells and a second cell set having a second group of energy storage cells connectable to the first cell set. The first cell set includes at least one first battery chemistry cell and the second cell set includes at least one second battery chemistry cell. At least one switch is in electrical communication with the first or second cell set. Battery connection terminals are in electrical communication with at least one of the first or second cell sets. A controller is configured to determine an operating strategy of the high-voltage battery pack assembly and place at least one of the first cell set or the second cell set in electrical communication with the battery connection terminals in response to the operating strategy of the high-voltage battery pack.

Abstract: A pressure management system includes a pressure plate disposed at an initial position relative to a battery cell, the battery cell disposed in a housing, the pressure plate and the housing defining an enclosure, where an increase in an internal pressure of the battery cell causes an expansion force to be applied to the pressure plate. The system includes a mechanical linkage attached to the pressure plate, the mechanical linkage configured to translate the expansion force to a reverse force that is opposed to the expansion force, and a rotatable component connected to the mechanical linkage, the rotatable component configured to rotate from a first orientation to a second orientation based on lateral movement of the mechanical linkage to allow the pressure plate to move and increase a volume of the enclosure.

Abstract: A vehicle includes two or more battery packs configured to power a motor. A controller is configured to dynamically activate an operational mode during operation. The operational mode is one of multiple possible operational modes including a first operational mode defining a series connection between the two or more battery packs and second operational mode defining a parallel connection between the two or more battery packs. The connection between the battery packs is controlled by a first plurality of switches. A plurality of low voltage loads are connected to a subset of the battery packs in the battery packs such that a power output of the subset of the battery packs provides full power to the plurality of low voltage loads. The plurality of low voltage loads are connected to only the subset of the battery packs in both the first operational mode and the second operational mode.

Abstract: A pressure management system includes a pressure plate disposed at an initial position relative to a battery cell, the battery cell disposed in a housing, where expansion of the battery cell causes an expansion force to be applied to the pressure plate. The pressure management system also includes a mechanical linkage attached to the pressure plate, the mechanical linkage configured to move in a lateral direction in response to the expansion force and translate the expansion force to a reactive force that is opposed to the expansion force, and a biasing system including a biasing member configured to resist lateral movement of the mechanical linkage. The biasing system is configured to apply a biasing force in a direction opposite the lateral direction, the biasing force causing the mechanical linkage to apply the reactive force as a selected proportion of the expansion force.

Abstract: A vehicle includes an apparatus for performing a method of controlling a pressure within a battery. The battery is disclosed between a support plate at a first side of the battery and a pressure plate disposed at a second side of the battery opposite the first side. The pressure plate is movable with respect to the support plate to control the pressure of the battery and including a first plate wedge. The first actuator wedge is moved parallel to the pressure plate with the first actuator wedge in contact with the first plate wedge to control a force applied by the first actuator wedge to the first plate wedge to move the pressure plate with respect to the support plate. Moving the pressure plate controls the pressure within the battery.

Abstract: A pressure management system includes a pressure plate configured to be disposed at an initial position relative to a battery cell in a housing, the initial position including a first orientation, a tilting assembly configured to allow the pressure plate to change from a first orientation to a second orientation based on the expansion force being non-uniform. The system includes a mechanical linkage attached to the pressure plate and configured to move laterally in response to the expansion force and translate the expansion force to a reactive force, and a biasing system including a biasing member configured to resist a lateral movement of the mechanical linkage. The biasing system is configured to apply a biasing force that causes the mechanical linkage to apply the reactive force, and based on the expansion force being non-uniform, is controllable to change the biasing force to balance an internal pressure of the cell.

Abstract: A vehicle includes a propulsion system having multiple electric motors. A battery system is connected to the electric motors via a direct current to direct current (DC-DC) converter and an inverter. The battery system includes a battery assembly having a plurality of battery modules. Each of the battery modules has multiple individual battery cells arranged in battery packs, a set of sensors configured to monitor a set of parameters of each battery pack, and a plurality of battery pack mounts. Each battery pack mount includes a base plate and a top plate and an actuator configured to alter a distance between plates. A monitoring unit is configured to monitor a value representative of a battery pack pressure, determine whether the value falls within a pressure threshold window, and maintain the value within the pressure threshold window by actively altering the battery pack pressure.

Abstract: Excessive expansion of rechargeable batteries during recharging is a significant concern since the uncontrolled buildup of high internal battery pressures from expansion inside a confined space can lead to separator membrane failure and/or thermal runaway of a battery cell. A crushable foam or honeycomb insert layer is placed inside of a rigid battery fixture to automatically limit the progressive buildup of internal battery pressure due to charging-induced expansion of the battery cell during recharging. The crushable insert layer is included as part of the rigid battery fixture. Aluminum honeycomb cores and porous aluminum metal foam materials have a significant amount of crushability over a very wide range of compressive strains. Alternatively, a porous metal foam or metal honeycomb material may be infused with a liquid polymer (e.g., silicone, rubber, EDPM, or polyurethane) to enhance the mechanical properties of the polymer-infused metal foam or honeycomb metal/polymer composite material.

Abstract: A pressure control apparatus for a battery cell includes a housing in which the battery cell is positioned, and a cell plate movably positioned in the housing and separating an interior of the housing into a cell chamber having the battery cell therein, and a pressure chamber having a volume of pressurized fluid therein. The apparatus further includes a valve configured to allow a portion of the pressurized fluid to be removed from the pressure chamber when the pressure in the pressure chamber exceeds a threshold.

Abstract: A vehicle includes a pressure control device for controlling a pressure at a battery of a vehicle and a method of controlling the pressure of the battery. A support plate is disposed at a first side of the battery. A pressure plate disposed at a second side of the battery opposite the first side. The pressure plate movable with respect to the support plate to control the pressure of the battery. A cam disposed at the pressure plate is configured to rotate to move the pressure plate with respect to the support plate. A cam shaft rotates the cam to move the pressure plate. A motor generates a rotation at the cam shaft.

Abstract: Aspects of the disclosure include a battery management system that actively limits the operational voltage of a cell to avoid a cell pressure surge in response to an indicator of battery cell degradation. An exemplary battery management system can include a memory, computer readable instructions, and one or more processors that perform operations that include: measuring a first cell pressure of a cell of the battery pack at a reference voltage and measuring a second cell pressure of the cell of the battery pack at the reference voltage. A moving average of cell pressure progression is determined from the first cell pressure and the second cell pressure. Responsive to the moving average of cell pressure progression exceeding a cell pressure progression threshold, the cell of the battery pack is identified as a degraded cell and an estimate of remaining cycles for the degraded cell is determined.

Abstract: A vehicle, a pressure control device and method for controlling a pressure within a battery of the vehicle. The pressure control device includes a support plate, a pressure plate and an actuator. The pressure plate is configured to move with respect to the support plate. The battery is disposed between the support plate and the pressure plate. The actuator changes between a first shape and a second shape to move the pressure plate with respect to the support plate to control the pressure within the battery.

Abstract: A vehicle includes at least one electric motor configured to convert electric power to rotational motion, a battery system electrically connected to the at least one electric motor, and a controller coupled to the battery system. The controller includes a non-transitory computer readable memory and a processor. The memory stores a charging control software module configured to cause the processor to perform the method of: determining an optimum charging profile based at least partially on an available received charging power, an ambient temperature of the battery system, charging system constraints, and at least one driver preference.

Abstract: A vehicle includes two or more battery packs configured to power a motor. A controller is configured to dynamically activate an operational mode during operation. The operational mode is one of multiple possible operational modes including a first operational mode defining a series connection between the two or more battery packs and second operational mode defining a parallel connection between the two or more battery packs. The connection between the battery packs is controlled by a first plurality of switches. A plurality of low voltage loads are connected to a subset of the battery packs in the battery packs such that a power output of the subset of the battery packs provides full power to the plurality of low voltage loads. The plurality of low voltage loads are connected to only the subset of the battery packs in both the first operational mode and the second operational mode.

Abstract: A method for controlling a vehicle charging and thermal operation includes monitoring at least a charge characteristic of a battery system and a thermal characteristic of the battery system. The method predicts a battery system temperature at a future time (t) based at least in part on the monitored characteristics using a predictive physics model and maintains the battery system temperature above a minimum temperature threshold and below a maximum temperature threshold by adjusting a charging profile based at least in part on the predicted battery system temperature.

Abstract: A trip energy estimation system for a vehicle includes a traffic speed module configured to determine an average traffic speed along a projected route, a path information module configured to output path information indicating route features along the projected route, a perceived speed module configured to output a perceived vehicle speed along the projected route based on the average traffic speed and the path information, and a dynamic driving module configured to calculate and output a predicted driver speed based on the perceived vehicle speed and a feedback input indicative of the predicted driver speed. The dynamic driving module is configured to execute a machine learning algorithm to calculate the predicted driver speed.

Abstract: Catastrophic capacity failure in Lithium Metal Battery (LMB) cells is preceded by an increase in battery resistance. At a fixed temperature, the onset of failure occurs at the same value of resistance across the cell(s). Various embodiments use this phenomenon as a prognostic for predicting when such a failure is likely to occur. In various aspects, a normalized resistance in a vehicle or other device may be detected and compensated for temperature differences. The compensated resistances, a threshold state of charge (SOC), and capacity differences may be used to predict capacity failure in remaining capacity or distance (e.g., miles), to identify failing LMB cells, and to send a prognostic alert.