CN108649595B

CN108649595B - Battery energy storage system, control system thereof and application thereof

Info

Publication number: CN108649595B
Application number: CN201810422475.8A
Authority: CN
Inventors: 维杰·李·比斯顿; 罗伯特.纳尔逊.泰瑞尔
Original assignee: Powin Energy Corp
Current assignee: Powin Energy Corp
Priority date: 2017-12-18
Filing date: 2018-05-05
Publication date: 2021-10-22
Anticipated expiration: 2038-05-05
Also published as: CN108649595A

Abstract

The invention provides a battery energy storage system, a control system and application thereof. The electrical energy storage unit may also be referred to as a battery energy storage system ("BESS"). In one embodiment, the electrical energy storage unit includes a battery system controller and a battery pack with an operating system. The battery pack comprises a single battery, a battery pack controller for controlling the single battery and a battery pack control system, wherein the battery pack control system comprises a series of modules including other modules, a battery endurance tracking module, a module for ensuring the effectiveness of the single battery in a quality guarantee period and an inverter balancing module. The inverter balancing module controls the power supply amount in the battery unit. In one embodiment, the battery cell is a lithium ion battery cell.

Description

Battery energy storage system, control system thereof and application thereof

Technical Field

The present invention generally relates to an electrical energy storage device. More particularly, the present invention relates to a modular, stacked battery energy storage unit and control system and applications thereof.

Background

Electric energy is vital to modern national economy. However, the increased demand for electrical energy and the trend of increasing renewable energy assets for power generation puts pressure on aging power infrastructure, which makes it more prone to failure, particularly during peak demand. In certain areas, the increased demand causes peak demand periods to dangerously approach, exceed, the maximum power supply level that the power industry can generate and deliver. Described herein are new energy storage systems, methods, and apparatus that allow for the generation and use of electricity in a more cost-effective and reliable manner.

Disclosure of Invention

The invention provides a modular and stacked electric energy storage unit and a control system and application thereof. The electrical energy storage unit may also be referred to as a battery energy storage system ("BESS"). In one embodiment, the electrical energy storage unit includes a battery system controller and a battery pack having a battery pack control system. Each battery pack is provided with a single battery, a battery pack controller for regulating and controlling the single battery and a battery pack control system, wherein the battery pack control system comprises a series of modules including other modules, a battery endurance tracking module, a module for ensuring the effectiveness of the single battery in a quality guarantee period and a balancing module. The balancing module controls the power supply amount in the battery unit. In one embodiment, the battery cell is a lithium ion battery cell.

In one embodiment, the battery pack may be a modular, stacked battery cell. A plurality of the battery cells are connected with a stacked battery controller or a serial battery controller to form a stacked battery. One or more of the stacked batteries may constitute an electrical energy storage unit or system.

In one embodiment, the cell equalizer includes a resistor that discharges the cells. In another embodiment, the cell balancing equalizer includes a capacitor, an inductor, or both to transfer electrical energy between the cells.

In one embodiment, the amp-hour monitor calculates an amp-hour value issued by the battery pack controller to determine the state of charge in each cell.

In one embodiment, a relay controller operates relays that control charging and discharging of the battery cells, as well as other functions, such as turning cooling fans on and off, controlling power supplies, and the like.

In one embodiment, the battery pack operating system includes a module that generates battery data that is received by the data center and analyzed to determine price data for the premium sales. In one embodiment, battery data may be received from a network-connected battery pack over the internet, the battery data being stored in a data center for generating premium rate data.

The invention is characterized in that the energy storage unit and the control system are highly scalable, ranging from small kilowatt-hour-level electrical energy storage units to megawatt-hour-level electrical energy storage units. The invention is also characterized in that it is possible to control and balance the cells in accordance with cell state of charge calculations other than by cell voltage.

Further embodiments, features, and advantages, as well as the structure and operation of various embodiments of the present invention, are described in greater detail below with reference to the accompanying drawings.

Drawings

The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate the present invention and together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the embodiments disclosed herein.

FIG. 1A is a block diagram illustrating an electrical energy storage unit comprising one or more battery packs assembled in one embodiment;

FIG. 1B is a diagram showing a battery pack having an operating system that collects and generates battery rate data for selling battery insurance in one embodiment;

FIG. 1C is a diagram showing a battery pack operating system in one embodiment;

FIG. 1D is a diagram showing an electrical energy storage unit in one embodiment;

FIG. 2A is a diagram showing the electrical energy storage unit of FIG. 1D in use in connection with a windmill;

FIG. 2B is a diagram showing the electrical energy storage unit of FIG. 1D in use in connection with a solar panel;

FIG. 2C is a diagram showing the electrical energy storage unit of FIG. 1D in use in connection with an electrical circuit;

fig. 3 is a diagram showing a battery pack in an embodiment;

fig. 4 is a diagram further illustrating a battery pack of an embodiment;

fig. 5 is a diagram showing a battery pack controller of an embodiment;

fig. 6A is a diagram showing a cell equalizer of an embodiment;

fig. 6B is a diagram showing a cell equalizer of an embodiment;

fig. 6C is a diagram showing a cell equalizer of an embodiment;

FIG. 7 is a diagram showing an electrical energy storage unit in one embodiment;

8A,8B and 8C are diagrams showing a battery system controller of an embodiment;

FIG. 9 is a diagram showing an electrical energy storage unit of an embodiment;

FIG. 10A is a diagram showing an electrical energy storage unit of an embodiment;

FIG. 10B is a diagram showing an electrical energy storage system of an embodiment;

FIG. 10C is a diagram showing an electrical energy storage system of an embodiment;

FIG. 11 is a diagram showing an electrical energy storage system of an embodiment;

FIG. 12 is a diagram showing an electrical energy storage system of an embodiment;

FIG. 13 is a diagram showing an electrical energy storage system of an embodiment;

FIG. 14 is a diagram showing an electrical energy storage system of an embodiment;

FIG. 15 is a diagram showing an electrical energy storage system of an embodiment;

FIG. 16 is a diagram showing an electrical energy storage system of an embodiment;

FIG. 17 is a diagram showing an electrical energy storage system of an embodiment;

FIG. 18 is a diagram showing an electrical energy storage system of an embodiment;

19A,19B,19C,19D and 19E are diagrams illustrating a typical user interface of an electrical energy storage unit of an embodiment;

FIG. 20 is a diagram showing an electrical energy storage unit of an embodiment;

FIG. 21 is a diagram showing typical battery data used by an embodiment of an electrical energy storage unit;

FIGS. 22A and 22B are diagrams illustrating typical battery data used by an embodiment of an electrical energy storage unit;

FIGS. 23A and 23B are diagrams illustrating typical battery data used by an embodiment of an electrical energy storage unit;

fig. 24A and 24B are diagrams showing the operation of an electrical energy storage unit of an embodiment;

FIG. 25 is a diagram showing operation of an electrical energy storage unit of an embodiment;

26A,26B,26C and 26D are diagrams of a classic battery pack showing an embodiment;

fig. 27A is a diagram showing a communication network scenario consisting of a battery pack controller and a plurality of battery module controllers according to an embodiment;

fig. 27B is a diagram showing one example of a flow of a battery module controller receiving an instruction;

fig. 28 is a diagram showing one example of a battery pack controller of an embodiment;

fig. 29 is a diagram showing one example of a battery module controller of an embodiment;

FIG. 30 is a diagram showing one example of a string controller of an embodiment;

FIGS. 31A and 31B are diagrams showing a sample of a string controller of an embodiment;

FIG. 32 is a flow diagram of an example scheme for balancing battery packs;

FIG. 33 is a graph illustrating the correlation between current measurements and current coefficients used to calculate a warranty value, according to one embodiment;

FIG. 34 is a graph illustrating a correlation between temperature measurements and temperature coefficients used to calculate a warranty value, according to an embodiment;

FIG. 35 is a graph illustrating a correlation between voltage measurements and voltage coefficients used to calculate a warranty value, according to one embodiment;

FIG. 36A is a diagram illustrating how one embodiment determines a battery life value or shelf life;

fig. 36B is a diagram showing (demonstrating) a warranty threshold for validating the warranty of a battery pack according to an embodiment;

fig. 37 is a diagram illustrating an example use of a battery pack of an embodiment;

FIG. 38 is a diagram illustrating an example warranty tracker in accordance with an embodiment;

FIG. 39 is a diagram illustrating an example method used by one embodiment to calculate and store cumulative warranty values;

FIG. 40 is a diagram illustrating an example method of using a warranty tracker of an embodiment;

FIG. 41 is a diagram illustrating a battery pack and associated warranty information, according to one embodiment;

FIG. 42 is a diagram illustrating an example distribution of battery packs based on self-discharge rate and charge time for an embodiment;

FIG. 43 is a graph illustrating the relationship between temperature and charge time of a battery pack according to one embodiment;

FIG. 44 is a diagram illustrating an example system for detecting a battery pack having an operational problem or defect according to one embodiment;

FIG. 45 is a diagram illustrating one embodiment of obtaining aggregate data from a battery array for analysis;

FIG. 46 is a flow chart illustrating an example method for detecting a battery pack having an operational problem or defect according to an embodiment;

FIG. 47 depicts a cross-sectional view of an example BESS and an example view of a deployment of one or more BESS units;

FIG. 48A is a diagram illustrating an example BESS coupled to an example energy management system;

FIG. 48B is a diagram depicting a cross-sectional view of an example BESS;

fig. 49A, 49B, and 49C are diagrams illustrating an enclosure of an example BESS;

fig. 50A, 50B, and 50C are diagrams illustrating an example BESS with the housing of the BESS removed;

fig. 51 is a diagram illustrating air flow in an example BESS.

FIGS. 52A and 52B are diagrams illustrating an example BESS connection to a bi-directional converter;

FIGS. 53A and 53B are diagrams illustrating an example BESS;

FIGS. 54A, 54B and 54C are diagrams illustrating an example BESS installed in a modified shipping container;

FIGS. 55A, 55B,55C and 55D are diagrams illustrating an example of a modular, stacked BESS;

56A, 56B,56C,56D and 56E are diagrams showing a modular, stacked battery pack;

FIGS. 57A,57B,57C,57D,57E and 57F are diagrams illustrating a modular, stacked battery or cell;

FIGS. 58A,58B and 58C are diagrams illustrating a modular, stacked battery or cell;

fig. 59A,59B and 59C are views showing a battery assembly example of a modular, stacked battery pack or battery cell;

FIGS. 60A and 60B are diagrams illustrating an example stacked or serial battery controller;

61A,61B,61C and 61D are diagrams illustrating an example battery pack controller;

embodiments are described with reference to the drawings. The drawing in which an element first appears is generally indicated by the leftmost or corresponding reference numeral.

Detailed Description

The terms "embodiment" or "example embodiment" do not require that all embodiments include the discussed feature, advantage or mode of operation. Alternate embodiments may be devised without departing from the scope or spirit of the invention, and well-known elements may not be described in detail or may be omitted so as not to obscure the relevant details. Furthermore, the terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises," "comprising," "includes" and "including," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or groups thereof.

In one embodiment, the electrical energy storage unit (which may also be referred to as a battery energy storage system ("BESS") includes a battery system controller and battery packs each having a battery cell, a battery pack controller that monitors the cells, a battery pack cell inverter and a battery pack charger that adjusts the energy stored in the cells.

As described herein, the present invention is characterized by energy storage units and control systems that are highly scalable, ranging from kilowatt-hour-scale electrical energy storage units to megawatt-hour-scale electrical energy storage units.

Fig. 1A is a block diagram illustrating the structure of an electrical energy storage unit 10 including one or more battery packs 104 in one embodiment. The illustrated electrical energy storage unit includes an energy storage unit 100, an energy storage unit 110, and an energy storage unit 120. the energy storage unit 100 includes a separate battery pack 104 c. The energy storage unit 120 includes two

battery packs

104d and 104 e. In general, the energy storage unit may include any number of battery packs 104.

As shown in fig. 1A, the connected battery pack 104 is connected to a data center 140 and is capable of transmitting data over the network 130. Data from battery pack 104 may be automatically sent to data center 140 or sent to data center 140 in response to a signal sent to energy storage units 100,110, and 120 through data center 140.

Fig. 1B is a diagram showing a battery pack 104 having an operating system 150 in one embodiment, the operating system 150 generating battery rate data for a battery insurance 170 for sale by collecting battery data 160. In one embodiment, the battery pack operating system 150 is a series of modules having many of the functions described below. Data center 140 is any data center that can store battery data. In one embodiment, the battery data includes data that predicts battery life, data that represents battery usage, and data that relates to battery warranty. This data includes, for example: voltage data, battery temperature data, battery charge and discharge status data, and charge data. In one embodiment, the data corresponds to a particular battery module, a particular battery manufacturer, and a particular battery pack and energy storage system manufacturer.

In one embodiment, the battery data 160 (sample data stored in the data center 140) is analyzed and used to develop data for insurance purposes. For example, the battery data may be analyzed to determine an expected endurance time for a particular manufacturer-produced battery or a particular manufacturer-produced battery pack. This expected duration data may be used to determine an insurance sales cost for affixing to the battery pack 104. Batteries and battery packs with longer endurance have the potential for lower insurance coverage than batteries and battery packs with shorter endurance. In an embodiment, the ratio data is likewise used to determine the endurance insurance rate data.

The battery data 160 may be collected, analyzed, and used to generate insurance rate data, such as described in detail below.

Fig. 1C is a diagram further illustrating an embodiment battery pack operating system 150. As shown, a particular battery pack operating system 150 includes a battery duration monitor 162, a battery quality life monitor 164, a battery usage monitor 168, a battery alarm, an alert message and error (AWE) controller 151, a battery maintenance controller 152, a battery inverter controller 153, a battery calibration controller 154, a battery configuration controller 155, a battery communication controller 156, and a battery software update controller 157.

The battery endurance controller 162 tracks the endurance usage of the battery. In one embodiment, referring to fig. 36A, the process is described in detail below with respect to how the battery life value is calculated. This value is the result of multiplying the three factors and then continuing to accumulate. The three factors are a real-time status factor, a voltage factor and a temperature factor, which are further described below with reference to fig. 33,34 and 35. When the battery is used at a high charge rate or a high discharge rate, the endurance value thereof is increased at a higher rate than when it is used at a low charge rate or a low discharge rate. When the battery is not being charged or discharged, the battery endurance value does not increase. Likewise, the rate at which the battery endurance value increases is also related to the voltage factor and the temperature factor.

The battery life controller 164 ensures that the battery complies with life requirement specifications, such as those provided by the battery manufacturer. The battery life controller 164 measures a battery life state when it is abnormal and transmits the abnormal state of life information to the control center. In one embodiment, the user of the battery is also notified of the abnormal life condition. This is described in detail below with reference to fig. 36B.

The battery usage monitor 168 records data for analysis to determine how the battery was used before the end of the endurance time. In one embodiment, the data includes voltage data, temperature data, real-time status data, and electrical quantity data. In one embodiment, the data is presented in a usage data table. This is described in detail below with reference to fig. 37.

A battery alarm, warning message and error (AWE) controller 151 protects the battery and identifies operational problems. In one embodiment, the alarm, warning message and error message may include, for example: overvoltage conditions, over-temperature rate conditions, high charge current, high discharge current, communication failures, circuit board problems or failures, and failure or deterioration of a cell or battery module.

The battery maintenance controller 152 reports the problem with the battery pack to correct by maintenance.

The battery equalization controller 153 equalizes the batteries in a reliable and efficient manner, as described in more detail below.

The battery calibration controller 154 calibrates the values of the battery pack such as the state of charge, the amp hour capacity value, the watt hour capacity value, the voltage value calibration factor and the temperature value calibration factor.

The battery configuration controller 155 includes plug and play features for other battery packs. This involves establishing communication with other components of the energy cell, such as when the battery pack is powered on for the first installation, acquires a communication ID address and connects to a particular network of battery packs to form an energy storage cell.

The battery communication controller 156 monitors communications between the battery pack and other system components to ensure safe and reliable operation of the battery pack. It may also attempt to establish communication in the event of communication failure.

The battery software update controller 157 enables and facilitates remote updating of the battery pack software and the software resident on the battery. The update may be done automatically when the update feature is activated.

Fig. 1D is a diagram illustrating an electrical energy storage unit 100 according to an embodiment of the invention. As shown in fig. 1A to 1D, the electric energy storage unit 100 includes

battery units

104a and 104b,

control units

106a and 106b, and

inverters

108a and 108 b. In one embodiment, electrical energy storage unit 100 is enclosed in a container 102 that is smaller than a shipping container. In a similar embodiment, electrical energy storage unit 100 is mobile and can be transported by truck.

As shown in fig. 2A-2C, the electrical energy storage unit 100 is adapted to store a large amount of electrical energy.

FIG. 2A is a diagram illustrating the use of the electrical energy storage unit 100 of FIG. 1D as a part in a renewable wind energy system 200. Wind energy system 200 includes

wind turbines

202a and 202 b. Energy in wind turbine 202a is stored in electrical energy storage unit 100 a. The energy in wind turbine 202b is stored in electrical energy storage unit 100 b. As will be appreciated by those skilled in the art, the electrical

energy storage units

100a and 100b are capable of storing electrical energy generated and transmitted by the

wind turbines

202a and 202 b.

Fig. 2B is a diagram illustrating the use of electrical energy storage voltage 100 of fig. 1D as a part in renewable solar energy system 220. Solar energy system 220 includes a solar array 222 and an electrical energy storage unit 100 energy from solar array 222 is stored in electrical energy storage unit 100. Electrical energy storage unit 100 is capable of storing electrical energy generated concurrently from solar array 222.

Fig. 2C is a diagram illustrating the use of 1D electrical energy storage voltage 100 as a part of renewable grid energy system 230. Grid energy system 230 includes electrical energy devices 232 and electrical energy storage unit 100. energy sources in grid energy system 230 are primarily in electrical energy storage unit 100. The electric energy stored in the electric energy storage unit 100 may be transmitted.

Fig. 3 is a diagram further illustrating the

battery cells

104a and 104b of the battery storage unit 100. As shown in fig. 3, according to an embodiment, the

battery cells

104a and 104b are composed of a plurality of battery packs 301. In fig. 3, three battery packs 302a-c are shown. Battery packs 302a and 302c are an integral part of battery cell 104 a. Battery pack 302b is an integral part of battery unit 104 b.

Fig. 4 is a diagram illustrating a battery pack 302 in a further embodiment of the present invention. The battery pack 302 includes a housing 402, a cover 404, a power connector 406, and two

signal connectors

408a and 408 b. Housing 402 and cover 404 are made of a preferably strong plastic or metal. The power connectors 406 include connectors for the positive and negative ports of the battery pack, connectors for the direct current supply of power, and connectors for the alternating current supply of power. In one embodiment of the present invention, only the dc supply power and the ac supply power may be used. The

signal connectors

408a and 408b are RJ-45 connectors, but other types of connectors may be used. The signal connector may be used for communication between, for example, the battery pack 302 and other components of the battery storage unit 100.

As shown in fig. 4, in one embodiment, the housing 402 encloses a battery lifter plate 410 that supports two

battery modules

412a and 412 b. Each

battery module

412a and 412b includes a plurality of push-pull batteries coupled together in a series of configurations. In one embodiment,

battery modules

412a and 412b include, but are not limited to, for example: a 1P16S configuration, a 2P16S configuration, a 3P16S configuration, or a 4P16S configuration provided with a 10-50AH monomer. Other configurations may also form part of the scope of the present invention. In one embodiment, the cells are connected together by a printed circuit board that includes monitoring battery voltage, temperature and inverter cells.

Other components enclosed in the housing 402 include a battery pack controller 414, an ac power supply 416, a dc power supply 418, a cell balancer 420, and a fuse and fuse box 422. In one embodiment of the present invention, only an AC power supply 416 and a DC power supply 418 are utilized.

Fig. 5 is a diagram further illustrating the battery pack controller 414 in an embodiment of the invention. In one embodiment, the battery pack controller 414 includes a battery/DC input circuit 502, a charge conversion circuit 504, a DIP-switch 506, a JTAG connector 508 and an RS-232 connector 510, a fan connector 512, a CAN (CAN bus) connector 514, a micro-processing unit (MCU)516, a memory 518, an equalizer board connector 520, a battery pack (case) temperature monitoring circuit 522, a cell temperature measurement circuit 524, a cell voltage measurement circuit 528, a DC-DC power supply 530, a watchdog timer 532 and a reset button 534. the cell temperature measurement circuit 524 and the cell voltage measurement circuit 528 are connected to the MCU516 via Multiplexers (MUXs) 526a and 526b, respectively.

In one embodiment, the power for the battery pack controller 414 is derived from the energy stored in the battery cells to which the battery pack controller 414 is coupled via the battery/dc input circuit 502. In another embodiment, the battery pack controller 414 draws power from a dc power supply that is connected to the battery/dc input circuit. The dc-dc power supply 530 then converts the input dc power to one or more power standards that are appropriate for the power components of the different battery pack controllers.

The charge conversion circuit 504 is connected to the MCU 516. The charge conversion circuit 504 and the MCU516 are used to control the operation of the ac power supply 416 and the dc power supply 418. An ac power supply 416 and/or a dc power supply 418 are used to supply power to the cells of the battery pack 302, as described herein.

The battery pack controller 414 includes a plurality of interfaces and connectors for communication. The interface and connector are connected to the MCU516 as shown in FIG. 5. In one embodiment, the interface and connector includes: a DIP-switch 506 for setting a part of information of a software for identifying the battery controller 414; JTAG connector 508, which is used to test and troubleshoot faults for battery controller 414; an RS-232 connector 510 for communication with the MCU 615; and an inverter board connector 520 for transmitting signals with the battery controller 414 and the cell inverter 420.

The fan connector 512 is connected to the MCU 516. The fan connector 512 is used to interface with the MCU516 and the battery pack circuit monitoring circuit 522 so that one or more optional fans that help dissipate heat from the battery pack 302 operate. In one embodiment, the battery pack circuit monitoring circuitry 522 includes a plurality of temperature sensors for monitoring the temperature of the cell inverter 420 and other heat sources internal to the battery pack 302, such as: the temperature of the ac power supply 416 and the dc power supply 418.

A micro processing unit (MCU)516 is coupled to a memory 518. MCU516 is configured to execute applications that govern battery pack 302. As described herein, in one embodiment an application performs the following functions: monitoring the voltage and temperature of the cells of battery pack 302, inverting the cells of the battery pack, monitoring and controlling (if necessary) the temperature of battery pack 302, processing communications between battery pack 302 and other components of electrical energy storage system 100, generating alarm messages or issuing alarms, and having other suitable actions to prevent overcharging and overdischarging of the cells of battery pack 302.

Cell temperature measurement circuit 524 is used to monitor the cell temperature of battery pack 302. In one embodiment, the separate temperature monitoring channels are connected to the MCU516 through a Multiplexer (MUX)526 a. The read temperature data is used to ensure that the battery cell operates within a specific temperature range set by the battery cell, and adjust the associated temperature values in the application program executed in the MCU516, such as: how much power is still available in battery pack 302 for discharge.

The cell voltage measurement circuit 528 is used to monitor the cell voltage of the battery pack. In one embodiment, a separate voltage monitoring channel is connected to MCU516 through Multiplexer (MUX)526 b. The read voltage data may be used, for example, to ensure that the battery cell is operating within its set voltage range and to calculate a dc power level.

The watchdog timer 532 is used to monitor and ensure proper operation of the battery pack controller 414. In the event of an unrecoverable error or an unscheduled infinite software loop during operation of the battery controller 414, the watchdog timer 53 may reset the battery controller 414 so that it automatically resumes operation.

The reset button 534 is used to manually reset the operation of the battery pack controller 414. As depicted in fig. 5, the reset button 534 is coupled to the MCU 516.

Fig. 6A is a diagram showing a battery cell inverter 420a according to an embodiment of the present invention. Battery cell inverter 420a includes a first set of resistors 604a-d coupled to cell connector 602a through switches 606a-d and a second set of resistors 604e-h coupled to cell connector 602a through switches 606 e-h.

Cell connectors

602a and 602b are used to connect battery cell inverter 420a to the cells of battery pack 302. A battery pack Electronic Control Unit (ECU) connector 608 connects the switches 604a-h to the battery pack controller 414.

In operation, switches 606a-h of battery cell inverter 420a are selectively opened and closed to vary the energy stored in the cells of battery pack 302. The selective opening and closing of switches 606a-h allows the energy stored in a particular cell of the battery pack to be discharged through resistors 604a-h, or energy to bypass selected cells during charging of the cells of battery pack 302. Resistors 604a-h are sized to allow a selected energy to be discharged from the cells of battery pack 302 for a selected amount of time and to allow the selected energy to bypass the cells during charging. In one embodiment, the closing of the switches 604a-h is inhibited by the battery pack controller 414 when the charge energy exceeds a selected bypass energy.

Fig. 6B is a diagram showing (demonstrating) the battery cell inverter 420B. Battery cell inverter 420b includes a first capacitor 624a coupled to two Multiplexers (MUX)620a through

switches

622a and 622b and a second capacitor 624b coupled to two Multiplexers (MUX)620c and 620d through switches 622c and 622.

Multiplexers

620a and 620b are connected to cell connector 602 a.

Multiplexers

620c and 620d are connected to cell connector 602 b. A battery pack Electronic Control Unit (ECU) connector 608 connects the switches 622a-d to the battery pack controller 414.

In operation, multiplexers 620a-b and switches 622a-b are first configured to connect capacitor 624a to the first cell of battery pack 302. After connection, the capacitor 624a is charged by the first cell, and this charging of the capacitor 624a reduces the energy stored in the first cell. After charging, multiplexers 620a-b and switches 622a-b are then configured to connect capacitor 624a to the second cell of battery pack 302. At this time, the energy stored in the capacitor 624a is discharged into the second battery cell, thereby increasing the energy stored in the second battery cell. By continuing this process, capacitor 624a transfers energy back and forth between the individual cells of battery pack 302, thus inverting the battery cells. In a similar manner, multiplexers 620c-d, switches 622c-d, and capacitors 624b are also used to transfer energy back and forth between the individual cells of battery pack 302 and to inverter the battery cells.

Fig. 6C is a diagram showing the battery cell inverter 420C. Battery cell inverter 420c includes a first inductor 630a coupled to two Multiplexers (MUX)620a through

switches

622a and 622b and a second inductor 630b coupled to two Multiplexers (MUX)620c and 620d through switches 622c and 622.

Multiplexers

620a and 620b are connected to cell connector 602 a.

Multiplexers

620c and 620d are connected to cell connector 602 b.

Cell connectors

602a and 602b are used to connect battery cell inverter 420a to the cells of battery pack 302. Inductor 630a is also connected to the cells of battery pack 302 by switch 632a and inductor 630b is also connected to the cells of battery pack 302 by switch 632 b. A battery pack Electronic Control Unit (ECU) connector 608 connects switches 622a-d and switches 632a-b to the battery pack controller 414.

In operation, switch 632a is first closed to allow energy from the batteries of battery pack 302 to charge inductor 630 a. This charging removes energy from the cells of battery pack 302 and stores the energy in inductor 630 a. After charging, multiplexers 620a-b and switches 622a-b are configured to connect inductor 630a to a selected cell of battery pack 302. Upon connection, the inductor 630a discharges its stored energy into the selected cell, thereby increasing the energy stored in the selected cell. By continuing this process, inductor 630a thus serves to take energy from the cells of battery pack 302 connected to inductor 632a through switch 632a and transfer this energy to only selected cells of battery pack 302. This process may be used to inverter cells of the battery pack 302. In a similar manner, multiplexers 620c-d, switches 622c-d and 632b, and inductor 630b are also used to transfer energy and cells of inverter battery pack 302.

As will be appreciated by those skilled in the relevant art, each of the circuits described in fig. 6A-6C are advantageous in their operation through the description herein, and in embodiments of the invention, the elements of these circuits are combined to bypass and/or transfer energy and thereby equalize the cells of battery pack 302.

Fig. 7 is a diagram further showing the electrical energy storage unit 100 according to an embodiment of the invention. As shown in fig. 7, the control unit 106 includes a plurality of battery system controllers 702 a-c. As will be described in greater detail below, each battery system controller 702 monitors and controls a subset of the battery packs 302 (see fig. 3) that make up the battery cells 104. In one embodiment, the battery system controllers 702 are linked together using can (canbus) communications that allow the battery system controllers 702 to operate together as part of an overall network of battery system controllers. This network of battery system controllers can manage and operate battery systems of any size, such as a plurality of megawatt-hour-scale centralized storage battery systems. In one embodiment, one of the networked battery system controllers 702 may be designated as the master battery system controller and used to control battery charging and discharging operations by sending commands that operate one or more inverters and/or chargers connected to the battery system.

As shown in fig. 7, in one embodiment, the electrical energy storage unit 100 includes a bi-directional inverter 108. The bi-directional inverter 108 can use commands issued over a network (e.g., the internet, ethernet, etc.) via a computer, for example, to charge the battery cells 104 and to discharge the battery cells 104, as described in more detail below with reference to fig. 10B and 10C. In an embodiment of the invention, the real and reactive power of the inverter 108 may be controlled. Also, in embodiments, the inverter 108 may operate as a backup power source when grid power is unavailable and/or the energy storage unit 100 is disconnected from the grid.

Fig. 8A is a diagram further showing the battery system controller 702 according to an embodiment of the present invention. As shown in fig. 8A, in one embodiment, the battery system controller 702 includes an embedded computer processing unit (embedded CPU)802, an amp hour/power monitor 806, a low voltage relay controller 816, a high voltage relay controller 826, a fuse 830, a shunt 832, a contactor 834, and a power supply 836.

As shown in fig. 8A, in one embodiment, embedded CPU802 communicates with amp hour/power monitor 806, low voltage relay controller 816, and battery pack 302 via can (canbus) communication port 804 a. In an embodiment, embedded CPU802 also communicates with one or more inverters and/or one or more chargers using, for example, can (canbus) communication, as described herein.

However, other communication means, such as RS232 communication or RS485 communication, may also be used. In operation, the embedded CPU802 performs a number of functions. These functions include: monitor and control selected functions of battery pack 302, amp hour/power monitor 806, low voltage relay controller 816, and high voltage relay controller 826; monitoring and controlling when battery pack 302 stores energy, how much and at what rate energy is stored, and when, how much and at what rate energy is discharged by battery pack 302; prevent overcharging or overdischarging of the cells of battery pack 302; configuring and controlling system communications; receiving and implementing commands, such as from an authorized user or another networked battery system controller 702; and provide status and configuration information to an authorized user or another networked battery system controller 702. These functions, as well as other functions performed by the embedded CPU802, are described in more detail below.

As described in more detail below, examples of the types of status and control information monitored and maintained by the embedded CPU802 include those identified with reference to fig. 19A-19E, fig. 21, fig. 22A-22B, and fig. 23A-23B. In an embodiment, the embedded CPU802 monitors and maintains conventional electrical system information such as inverter output power, inverter output current, inverter ac voltage, inverter ac frequency, charger output power, charger output current, charger dc voltage, and the like. Additional status and control information monitored and maintained by embodiments of the embedded CPU802 will also be apparent to persons of ordinary skill in the relevant art from the description herein.

As shown in FIG. 8A, ampere-hour/power monitor 806 includes CAN (CANBus) communication port 804b, Micro Control Unit (MCU)808, memory 810, current monitoring circuit 812, and voltage monitoring circuit 814. Current monitoring circuit 812 is coupled to current shunt 832 and is used to determine current values and monitor the charging and discharging of battery pack 302. Voltage monitoring circuit 814 is coupled to current shunt 832 and contactor 834 and is used to determine voltage values and monitor the charging and discharging of battery pack 302. The current and voltage values obtained by current monitoring circuit 812 and voltage monitoring circuit 814 are stored in memory 810 and communicated, for example, to embedded CPU802 using, for example, CAN (CANBus) communication port 804 b.

In one embodiment, the current and voltage values determined by the amp hour/power monitor 806 are stored in memory 810 and used by a program stored in memory 810 and executed on the MCU 808 to derive power, amp hour and watt values. These values and status information about amp hour/power monitor 806 are communicated to embedded CPU802 using can (canbus) communication port 804 b.

As shown in fig. 8A, the low voltage relay controller 816 includes a can (canbus) communication port 804c, a Micro Control Unit (MCU)818, a memory 820, a plurality of relays 822 (i.e., relays R0, R1.. RN), and a field effect transistor (MOSFETS) 824. In an embodiment, the low voltage relay controller 816 also includes temperature sensing circuitry (not shown) to monitor, for example, the temperature of the enclosure housing components of the battery system controller 702, the enclosure housing electrical energy storage unit 100, and the like.

In operation, the low voltage relay controller 816 receives commands from the embedded CPU802 via the CAN (CANBus) communication port 804c and operates the relay 822 and field effect transistor 824 accordingly. In addition, the low voltage relay controller 816 sends status information regarding the status of the relays and FETs to the embedded CPU802 via CAN (CANBus) communication port 804 c. The relay 822 is used to perform functions such as: turn a cooling fan on and off, control the output of a power source such as power source 836, and the like. The FET 824 is used to control the relay 828 of the high voltage relay controller 826 and to control status lights, etc. In an embodiment, low voltage controller 816 executes a program stored in memory 820 on MCU 818, MCU 818 taking over control of the operation of CPU802 in the event that the embedded PU ceases operation and/or communicates as desired. This program can then make a determination as to whether it is safe to continue operation of the system while waiting for embedded CPU802 to resume or whether a system shutdown and restart is initiated.

As shown in fig. 8A, high voltage relay controller 826 includes a plurality of relays 828. One of these relays is used to operate a contactor 834, and the contactor 834 is used to make or break connections in the current carrying lines connecting the battery pack 302. In an embodiment, other relays 828 are used, for example to control the operation of one or more inverters and/or one or more chargers. The relay 828 can operate either directly operating the device according to voltage and current considerations or by appropriately controlling additional contactors (not shown).

In an embodiment, the fuse 830 is included in the battery system controller 702. The purpose of the fuse 830 is to interrupt high currents that may damage the cells or the connecting wires.

Current shunt 832 is used in conjunction with amp hour/power monitor 806 to monitor the charging and discharging of battery pack 302. In operation, a voltage proportional to the current flowing through shunt 832 is developed across shunt 832. This voltage is sensed by current monitoring circuit 812 of amp hour/power monitor 806 and used to generate a current value.

Power supply 836 provides dc power to operate the various components of battery system controller 702. In an embodiment, the power input to power supply 836 is an ac line voltage, a dc battery voltage, or both.

Fig. 8B and 8C are diagrams further illustrating an exemplary battery system controller 702, according to an embodiment of the present invention. Fig. 8B is a top, front side view of an example battery system controller 702 with the top cover removed to facilitate showing the layout of the housed components. Fig. 8C is a top, left side view of the example battery system controller 702, with the top cover also removed to show the layout of the components.

As shown in fig. 8B, 8C, or both, the battery system controller 702 includes an enclosure 840 that houses the embedded CPU802, the amp hour/power monitor 806, the low voltage relay controller 816, the high voltage relay controller 826, the fuse holder and fuse 830, the shunt 832, the contactor 834, and the power source 836. Also included within the enclosure 840 are a circuit breaker 842, a power switch 844, a first set of signal connectors 846 (on the front side of the enclosure 840), a second set of signal connectors 854 (on the back side of the enclosure 840), a set of power connectors 856a-d (on the back side of the enclosure 840), and two

high voltage relays

858a and 858 b. In fig. 8B and 8C, the routing has been purposely omitted to more clearly show the placement of the components, however, the manner in which these components are routed will be understood by those skilled in the relevant art from the description herein.

The purpose and operation of embedded CPU802, ampere hour/power monitor 806, low voltage relay controller 816, high voltage relay controller 826, fuse holder and fuse 830, shunt 832, contactor 834, and power supply 836 have been described above with reference to fig. 8A. The purpose of the circuit breaker 842 is safety, as known to those skilled in the relevant art. A circuit breaker 842 is in series with the shunt 832 and is used to interrupt high currents that may damage the cells or the connecting wires. It may also be used to manually disconnect current carrying lines connecting battery packs 302 together during maintenance or during periods when electrical energy storage unit 100 is not in use. Likewise, power switch 844 is used to turn on and off the ac power input to battery system controller 702.

The purpose of the first set of signal connectors 846 (on the front side of the enclosure 840) is to enable connection to the embedded CPU802 without having to remove the battery system controller 702 from the control unit 106 and/or without having to remove the top cover of the enclosure 840. In one embodiment, the first set of signal connectors 846 includes a USB connector 848, an RJ-45 connector 850, and a 9-pin connector 852. Using these connectors, a keyboard and a display (not shown) can be connected to the embedded CPU802, for example.

The purpose of the second set of signal connectors 854 (on the back side of enclosure 840) is to be able to connect to and communicate with other components of electrical energy storage unit 100, such as battery pack 302 and inverters and/or chargers. In one embodiment, the second set of signal connectors 854 includes an RJ-45 connector 850 and a 9-pin connector 852. RJ-45 connector 850 is used for CAN (CAN bus) communications and Ethernet/Internet communications, for example. The 9-pin connector 852 is used for, for example, RS-232 or RS-485 communications.

Power connectors 856a-d (on the back side of enclosure 840) are used to connect electrical conductors. In one embodiment, each power connector 856 has two larger current carrying connection pins and four smaller current carrying connection pins. One of the power connectors 856 is used to connect one end of the shunt 832 and one end of the contactor 834 to wires used to connect the battery pack 302 together (e.g., using two larger current carrying connection pins) and one or both of the

power sources

416 or 418 used to connect input power to the battery pack 302 to control one or more relays inside the enclosure 840 (e.g., using two or four of the four smaller current carrying connection pins). The second power connector 856 is used, for example, to connect mains ac power to a control relay within the housing 840. In an embodiment, the remaining two power connectors 856 are used, for example, to connect relays such as

relays

856a and 856b inside enclosure 840 to power supply current carrying conductors of an inverter and/or charger.

In an embodiment, the purpose of

high voltage relays

858a and 858b is to connect or disconnect current carrying conductors for power supply to the charger and/or inverter connected to battery pack 302. These relays can be used to prevent charger and/or inverter operation and thus protect the battery pack 302 from overcharging or overdischarging by interrupting the current carrying conductors of the charger and/or inverter connected to the battery pack 302.

Fig. 9 is a diagram showing an electrical energy storage unit 900 according to an embodiment of the invention. Electrical energy storage unit 900 as described herein can operate as a stand-alone electrical energy storage unit or it can be combined with other electrical energy storage units 900 to form part of a larger electrical energy storage unit, such as electrical energy storage unit 100.

As shown in fig. 9, electrical energy storage unit 900 includes a battery system controller 702 coupled to one or more battery packs 302 a-n. In an embodiment, as described in more detail below, the battery system controller 702 may also be coupled to one or more chargers and one or more inverters, represented in fig. 9 by inverter/charger 902.

The battery system controller 702 of the electrical energy storage unit 900 includes an embedded CPU802, an amp hour/power monitor 806, a low voltage relay controller 816, a high voltage relay controller 826, a fuse 830, a shunt 832, a contactor 834, and a power source 836. Each of the battery packs 302a-n includes a battery module 412, a battery pack controller 414, an ac power source 416, and a battery pack cell inverter 420.

For example, in operation, during battery charging, electrical energy storage unit 900 performs the following: the embedded CPU802 continuously monitors the condition information transmitted by the various components of the electrical energy storage unit 900, if based on such monitoring, the embedded CPU802 determines that the unit is operating properly, and then, upon command by an authorized user or by a program executing on the embedded CPU802 (see fig. 10B below), the embedded CPU802 sends a command to the low voltage relay controller 816 to close the MOSFET switch associated with the contactor 834. Closing this MOSFET switch activates the relay on the high voltage relay controller 826, which closes the contactor 834. Contactor 834 is closed to couple the charger (i.e., inverter/charger 902) to battery packs 302 a-n.

Once the charger is coupled to the battery packs 302a-n, the embedded CPU802 sends a command to the charger to begin charging the battery packs. In an embodiment, this command may be, for example, a charger output current command or a charger output power class command. After performing the self-test, the charger will start charging. This charging will cause current to flow through shunt 832, shunt 832 being measured by amp hour/power monitor 806. Amp hour/power monitor 806 also measures the total voltage of battery packs 302 a-n. In addition to measuring current and voltage, ampere hour/power monitor 804 calculates a dc power value, an ampere hour value, and a watt time value. The amp hour and watt hour values are used to update amp hour and watt hour counters maintained by the amp hour/power monitor 806. The current value, voltage value, amp hour counter value, and watt hour counter value are continuously transmitted by the amp hour/power monitor 806 to the embedded CPU802 and battery packs 302 a-n.

During charging, battery packs 302a-n continuously monitor transmissions from amp hour/power monitor 806 and update the values maintained by battery packs 302a-n using amp hour counter values and watt hour counter values. These values include battery and cell state of charge (SOC) values, battery and cell Ampere Hour (AH) dischargeable values, and battery and cell Watt Hour (WH) dischargeable values, just as described in more detail below with reference to fig. 21. Also, during the charging progression, embedded CPU802 continuously monitors transmissions from amp hour/power monitor 806 and transmissions from battery packs 302a-n and updates the values maintained by embedded CPU802 using the values transmitted by the amp hour counter and the values transmitted by battery packs 302 a-n. The values maintained by the embedded CPU802 include battery pack and cell SOC values, battery pack and cell AH dischargeable values, battery pack and cell WH dischargeable values, battery and cell voltages, and battery and cell temperatures, as described in more detail below with reference to fig. 22A and 22B. As long as each device is operating as intended, the charging progress will continue until the stopping criteria are met. In an embodiment, the stopping criterion comprises, for example, a maximum SOC value, a maximum voltage value, or a stopping time value.

During the progress of charging, when the stop criterion is satisfied, the embedded CPU802 sends a command to the charger to stop charging. Once charging is stopped, the embedded CPU802 sends a command to the low voltage relay controller 816 to open the MOSFET switch associated with contactor 834. Opening this MOSFET switch changes the relay state on the high voltage relay controller 826 associated with the contactor 834, which opens the contactor 834. Opening contactor 834 decouples the charger (i.e., inverter/charger 902) from the battery packs 302 a-n.

As described in more detail below, battery packs 302a-n are responsible for maintaining the normal SOC and voltage balance of their respective battery modules 412. In one embodiment, the normal SOC and voltage equalization is achieved by the battery pack using its battery pack controller 414 and/or its ac power source 416 to conform its battery modules 412 to target values transmitted by the embedded CPU802, such as target SOC values and target voltage values. Such an inverter occurs during a part of the charging progress or after the charging progress or both.

As will be appreciated by those skilled in the relevant art from the description herein, the discharge process of electrical energy storage unit 900 occurs in a manner similar to the charging process, except that battery packs 302a-n are discharged rather than charged.

Fig. 10A is a diagram further showing an electrical energy storage unit 100 according to an embodiment of the invention. As shown in fig. 10A, the electrical energy storage unit 100 is formed by combining and networking several electrical energy storage units 900A-n. Electrical energy storage unit 900a includes battery system controller 702a and battery pack 302a₁-n₁. Electrical energy storage unit 900b includes battery system controller 702n and battery pack 302a_n-n_n. The embedded CPUs 802a-n of the battery system controllers 702a-n are coupled together and communicate with each other using CAN (CANBus) communications. The information communicated between the embedded CPUs 802A-n includes information identified below with reference to FIG. 22A and FIG. 22B.

In operation, electrical energy storage unit 100 operates similar to that described above with respect to electrical energy storage system 900. Each battery system controller 702 monitors and controls its own components such as the battery pack 302. Further, one of the battery system controllers 702 operates as a master battery system controller and coordinates the activities of the other battery system controllers 702. Such coordination includes, for example, acting as a master monitor for electrical energy storage unit 100 and determining and communicating target values, such as target SOC values and target voltage values, that may be used to achieve proper battery pack balancing. More details on how this is achieved will be described below with reference to fig. 25.

Fig. 10B is a diagram of electrical energy storage system 1050, according to an embodiment of the invention. As shown in fig. 10B, in one embodiment, system 1050 includes electrical energy storage unit 100 in communication with server 1056. The server 1056 communicates with databases/storage devices 1058 a-n. Server 1056 is protected by firewall 1054 and is shown in communication with electrical energy storage unit 100 via internet 1052. In other embodiments, other communication means are used, such as cellular communication or advanced measurement architecture communication networks. Users of electrical energy storage system 1050, such as electrical utilities and/or renewable energy asset operators, interact with electrical energy storage system 1050 using user interface(s) 1060. In one embodiment, the user interface is a graphical, web-based user interface, for example, accessible by a computer directly connected to the server 1056 or the internet 1052. In an embodiment, the information displayed and/or controlled by the user interface(s) 1060 includes information such as that identified below with reference to fig. 19A-19E, 21, 22A-22B, and 23A-23B. Additional information as will be apparent to one of ordinary skill in the relevant art may also be included and/or controlled in view of the description provided herein.

In embodiments, user interface(s) 1060 may be used to update and/or change the programs and control parameters used by electrical energy storage unit 100. By varying the program and/or control parameters, a user can control the electrical energy storage unit 100 in any desired manner. This includes, for example, controlling when the electrical energy storage unit 100 stores energy, how much energy is stored, and at what rate, and when, how much, and at what rate energy is discharged by the electrical energy storage unit 100. In an embodiment, the user interface is capable of operating one or more electrical energy storage units 100 such that they respond, for example, as if rotating for standby and possibly prevent a power loss or outage.

In one embodiment, electrical energy storage system 1050 is used to learn more cell behavior. Server 1056 may be used, for example, to collect and process a large amount of information about the behavior of the cells making up electrical energy storage unit 100 and about electrical energy storage unit 100 itself. In an embodiment, the information collected about the cells and the electrical energy storage unit 100 may be used by the manufacturer to perform actions such as improving future batteries and to develop more efficient future systems, and the information may also be analyzed to determine issues such as how to operate the cells in a particular manner to affect the useful life of the cells and the electrical energy storage unit 100. Additional features and benefits of electrical energy storage system 1050 will be apparent to those skilled in the relevant art from the description provided herein.

Fig. 10C is a diagram of an electrical energy storage system 1050, according to an alternative embodiment of the present invention. A user of the electrical energy storage system 1050 may use a computer 1070 (a user interface may be provided on the computer 1070) to access the electrical energy storage unit 100 via a network connection 1080 other than the internet. Network 1080 in fig. 10C may be any network contemplated in the art, including an ethernet or even a single cable that directly connects computer 1070 to electrical energy storage unit 100.

Fig. 11 to 20 are diagrams further illustrating an electric energy storage unit according to the present invention and various electric energy storage systems employing the electric energy storage unit.

Fig. 11 is a diagram showing an electrical energy storage system 1100 according to an embodiment of the invention. The electrical energy storage system 1100 includes an electrical energy storage unit 900, a generator 1104, cell phone station equipment 1112, and cell phone towers and equipment 1114. As shown in fig. 11, the electrical energy storage unit 900 includes a battery 1102 having ten battery packs 302a-j, a battery system controller 702, a charger 1106, and an inverter 1108. In embodiments of the present invention, battery 110 may contain more or less than ten battery packs 302.

In operation, the generator 1104 operates and is used to charge the battery 1102 via the charger 1106. When battery 1102 is charged to a desired state, generator 1104 is turned off. The battery 1102 is then ready to power the cellular telephone station equipment 1112 and/or equipment on the cellular telephone tower. The battery system controller 702 monitors and controls the electrical energy storage unit 900 as described herein.

In an embodiment of the present invention, the inverter 1108 is operable while the charger 1106 is operating so that the inverter 1108 can provide power to the device without interruption during charging of the battery 1102. The electrical energy storage system 1100 may use backup power (e.g., when grid power is not available) or it may be continuously used in situations where grid power is not present (e.g., in an off-grid environment).

Fig. 12 is a diagram showing an electrical energy storage system 1200 according to an embodiment of the invention. Electrical energy storage system 1200 is similar to electrical energy storage system 1100 except that electrical energy storage unit 900 now supplies power to load 1202. The load 1202 may be any electrical load as long as the battery 1102 and the generator 1104 are of corresponding sizes.

The electrical energy storage system 1200 is suitable, for example, for off-grid environments, such as remote hospitals, remote schools, remote government agencies, and the like. Because the generator 1104 is not required to be continuously operated to power the load 1202, significant fuel savings can be achieved, as well as improved operational life of the generator 1104. Other savings can also be realized using the electrical energy storage system 1200, such as a reduction in the transportation cost of the fuel required to operate the generator 1104.

Fig. 13 is a diagram showing an electrical energy storage system 1300 according to an embodiment of the invention. The electrical energy storage system 1300 is similar to the electrical energy storage system 1200 except that the generator 1104 is replaced by a solar panel 1302. In the electrical energy storage system 1300, the solar panel 1302 is used to generate electricity that is used to charge the battery 1102 and to power the load 1202.

The electrical energy storage system 1300 is suitable for use in, for example, off-grid environments, similar to the electrical energy storage system 1200. One advantage of electrical energy storage system 1300 over electrical energy storage system 1200 is that no fuel is required. The absence of a generator and the absence of fuel requirements makes the electrical energy storage system 1300 easier to operate and maintain than the electrical energy storage system 1200.

Fig. 14 is a diagram showing an electrical energy storage system 1400 according to an embodiment of the invention. The electrical energy storage system 1400 is similar to the electrical energy storage system 1300 except that the solar panels 1302 are replaced by grid connections 1402. In electrical energy storage system 1400, grid connection 1402 is used to provide power for charging battery 1102 and powering load 1202.

The electrical energy storage system 1400 is suitable, for example, for environments where grid power is available. One advantage of the electrical energy storage system 1400 over the electrical energy storage system 1300 is that the initial purchase price is less than the purchase price of the electrical energy storage system 1400. Because it does not require a solar panel 1302.

Fig. 15 is a diagram showing an electrical energy storage system 1500 according to an embodiment of the invention. The electrical energy storage system 1500 includes an electrical energy storage unit 900 connected to the electrical grid via a grid connection 1402.

The electrical energy storage system 1500 stores and supplies energy from and to the grid, such as may help utilities shift peak loads and perform load balancing. As such, the electrical energy storage unit 900 may use a bi-directional inverter 1502 instead of using a separate inverter and a separate charger. The use of a bi-directional inverter is advantageous because it is generally less expensive than purchasing a separate inverter and a separate charger.

In an embodiment of the present invention, the electrical energy storage units 900 of the electrical energy storage system 1500 are operated remotely using a user interface and computer system, similar to that described above with reference to fig. 10B. Such a system enables the energy stored in battery 1102 to be apportioned in a manner similar to how utility operators interact to apportion energy from gas turbines.

Fig. 16 is a diagram showing an electrical energy storage system 1600 according to an embodiment of the invention. The electrical energy storage system 1600 includes an electrical energy storage unit 900 (housed in an outdoor enclosure 1602), the electrical energy storage unit 900 being coupled to a solar panel 1606 (mounted on the roof of a house 1640) and a grid connection 1608.

In operation, the solar panel 1606 and/or the grid connection 1608 can be used to charge the battery of the electrical energy storage unit 900. The batteries of the electrical energy storage unit 900 are then discharged to power loads within the house 1604 and/or to provide power to the grid via the grid connection 1608.

Fig. 17 is a diagram showing an electrical energy storage unit 900 housed in an outdoor enclosure 1602 according to an embodiment of the invention. As shown in fig. 17, the electrical energy storage unit 900 includes a battery 1102, a battery system controller 702, a charger 1106, and an inverter 1108, as well as a breaker box and breaker 1704. Electrical energy storage unit 900 operates in the manner described herein.

In one embodiment, the outdoor enclosure 1602 is a NEMA 3R rated enclosure. The enclosure 1602 has two doors mounted to a front side of the enclosure 1602 and two doors mounted to a rear side of the enclosure 1602 to facilitate access to the equipment within the enclosure. The top and side panels of the enclosure may also be removed for further access to the internal equipment. In an embodiment, the enclosure 1602 is cooled using a fan controlled by the battery system controller 702. In an embodiment, cooling is achieved by an air conditioning unit (not shown) mounted on one of the doors.

As will be appreciated by one of ordinary skill in the relevant art from the description herein, the invention is not limited to the use of the outdoor enclosure 1602 to house the electrical energy storage unit 900. Other enclosures may also be used.

As shown in fig. 18, in one embodiment of the invention, a computer 1802 is used to interact with the electrical energy storage unit 900 and control the electrical energy storage unit 900. The computer 1802 may be any computer, such as a personal computer running a Windows or Linux operating system. The connection between the computer 1802 and the electrical energy storage system 900 may be a wired connection or a wireless connection. Such a system for interacting with the electrical energy storage unit 900 is suitable, for example, for a user living in the premises 1604 desiring to use such a system. For other users, such as utility operators, a system similar to that described with reference to fig. 10B may be used, thereby providing further control to obtain more useful information in electrical energy storage unit 900.

In embodiments of the invention, the electrical energy storage unit 900 may be monitored and/or controlled by more than one party, such as by the occupants of the premises 1602 and by the utility operator. In these cases, different priorities of authorized users may be established to avoid any potentially conflicting commands.

Fig. 19A-19E are diagrams illustrating an exemplary user interface 1900 according to an embodiment of the invention, suitable for implementation on a computer 1802, for example. The illustrative interfaces are intended to be illustrative and not limiting of the invention.

In one embodiment as shown in fig. 19A, the user interface 1900 includes a condition indicator 1902, a stored energy indicator 1904, an electrical energy storage unit power value 1906, a house load value 1908, a solar power value 1910, and a grid power value 1912. Condition indicator 1902 is used to indicate an operating condition of electrical energy storage unit 900. Stored energy indicator 1904 is used to show how much energy can be used to discharge from electrical energy storage unit 900. The four

values

1906, 1908, 1910, and 1912 illustrate the rate and direction of energy flow for the components of the electrical energy storage system 1600.

In fig. 19A, a value 1906 represents energy flowing into the electrical energy storage unit 900 at a rate of 2.8 kw. The value 1908 represents energy flowing into the house 1604 at a rate of 1.2kw to power the load. The value 1910 indicates that energy is being generated by the solar panel 1606 at a rate of 2.8 kw. Value 1912 represents energy being drawn from grid connection 1608 at a rate of 1.2 kw. From these values, it can be determined that the system is operating and that the solar panel is generating electricity, the battery of the electrical energy storage unit is charged and energy is purchased from the utility at a rate of 1.2 kw.

Fig. 19B depicts the state of the electrical energy power system 1600 at a point in time when the solar panel is not producing energy, such as at night. The value 1906 represents energy flowing into the electrical energy storage unit 900 at a rate of 2.0 kw. The value 1908 represents energy flowing into the house 1604 at a rate of 1.1kw to power the load. The value 1910 indicates that the solar panel 1606 is not generating energy. Value 1912 represents energy being drawn from grid connection 1608 at a rate of 3.1 kw. From these values, it can be determined that the system is operating, and when the solar panel is not generating electricity, the battery of the electrical energy storage unit is charged and energy is purchased from the utility at a rate of 3.1 kw.

Fig. 19C depicts the state of the electrical energy power system 1600 at the point in time when the batteries of the electrical energy storage unit 900 are fully charged and the solar panels are generating electricity. A value 1906 indicates that the electrical energy storage unit 900 consumes power rather than generating power. The value 1908 represents energy flowing into the house 1604 at a rate of 1.5kw to power the load. The value 1910 indicates that energy is being generated by the solar panel 1606 at a rate of 2.5 kw. Value 1912 indicates that energy is provided to grid connection 1608 at a rate of 1.0 kw.

Fig. 19D depicts the state of the electrical energy power system 1600 at a point in time when the solar panels are not producing energy, such as at night, and when the electrical energy storage unit 900 is generating more power than is used to power the loads in the house 1604. The value 1906 represents energy flowing out of the electrical energy storage unit 900 at a rate of 3.0 kw. The value 1908 represents energy flowing into the house 1604 at a rate of 2.2kw to power the load. The value 1910 indicates that the solar panel 1606 is not generating energy. Value 1912 indicates that energy is provided to grid connection 1608 at a rate of 0.8 kw.

Fig. 19E depicts the state of the electrical energy power system 1600 at a point in time when the solar panels are not producing energy, such as at night, and when the power storage unit 900 is controlled to generate power needs of loads in the house 1604. The value 1906 represents energy flowing out of the electrical energy storage unit 900 at a rate of 2.2 kw. The value 1908 represents energy flowing into the house 1604 at a rate of 2.2kw to power the load. The value 1910 indicates that the solar panel 1606 is not generating energy. A value 1912 indicates that no energy is being drawn from or supplied to grid connection 1608.

As will be understood by one of ordinary skill in the relevant art after reviewing fig. 19A-19E and the description disclosed herein, the electrical energy storage system 1600 has many advantages for electrical consumers and utilities. These advantages include, but are not limited to, utilities that can balance their loads, provide backup power to customers in the event of a power outage, support plug-in electric vehicles and deploy and renewable energy sources (e.g., solar panels), provide better grid regulation and can improve distribution line efficiency.

Fig. 20-25 are diagrams showing various features of software of the present invention. In an embodiment, the software features are implemented using programmable memory and non-programmable memory.

Fig. 20 is a diagram showing how various features of the software of the present invention described herein are distributed among the components of an exemplary electrical energy storage unit 900. As shown in fig. 20, in one embodiment, the battery system controller 702 of the electrical energy storage unit 900 has three components that include software. The software is executed using a Micro Control Unit (MCU). These components are the embedded CPU802, the amp hour/power monitor 806 and the low voltage relay controller 816.

The embedded CPU802 includes a memory 2004, the memory 2004 storing an Operating System (OS)2006 and an application program (APP) 2008. Such software is executed using the MCU 2002. In one embodiment, this software is used together to receive input commands from a user using a user interface, and it provides the user with information about the condition of electrical energy storage unit 900 via the user interface. The embedded CPU802 operates the electrical energy storage unit 900 according to the received input commands as long as the commands do not place the electrical energy storage unit 900 in an undesirable or unsafe state. The input commands are used to control, for example, when to charge and discharge battery 1102 of electrical energy storage unit 900. The input commands are also used to control, for example, the rate at which battery 1102 is charged and discharged and how deep battery 1102 cycles during each charge-discharge cycle. The software controls the charging of battery 1102 by sending commands to a charger Electronic Control Unit (ECU)2014 of charger 1106. The software controls the discharge of battery 1102 by sending commands to an inverter Electronic Control Unit (ECU)2024 of inverter 1108.

In addition to controlling the operation of the charger 1106 and inverter 1108, the embedded CPU802, along with the battery packs 302a-302n and the amp-hour/power monitor 806, is used to manage the battery 1102. The software resident and executing on embedded CPU802, battery system controllers 414a-n of battery packs 302a-n, and amp-hour/power monitor 806 ensure that battery 1102 operates safely at all times and if appropriate measures need to be taken to ensure that battery 1102 is neither overcharged nor overdischarged, for example.

As shown in fig. 20, ampere-hour/power monitor 806 includes a memory 810, memory 810 storing application 2010. Such applications are executed using MCU 808. In an embodiment, application 2010 is responsible for keeping track of how much charge is going into battery 1102 during the progression of battery charging and how much charge is being removed from battery 1102 during the progression of battery discharging. This information is communicated to the embedded CPU802 and the battery system controller 414 of the battery pack 302.

The low voltage relay controller 816 includes a memory 820, and the memory 820 stores an application program 2012. Application programs 2012 execute using MCU 818. In an embodiment, application 2012 opens and closes relays and MOSFETs in response to commands from embedded CPU 802. In addition, it also sends status information about the state of the relays and MOSFET switches to the embedded CPU 802. In an embodiment, low voltage relay controller 816 also includes a temperature sensor that is monitored using application program 2012 and in some embodiments application program 2012 includes sufficient functionality so that low voltage relay controller 816 can take over embedded CPU802 and make decisions regarding shutting down and restarting electrical energy storage unit 900 when embedded CPU802 is not operating as expected.

The charger ECU 2014 of the charger 1106 includes a memory 2018, and the memory 2018 stores an application 2020. The MCU 2016 is used to execute an application 2020. In an embodiment, the application 2020 is responsible for receiving commands from the embedded CPU802 and operating the charger 1106 accordingly. The application 2020 also sends status information about the charger 1106 to the embedded CPU 802.

The inverter ECU 2024 of the inverter 1108 includes a memory 2028, and the memory 2028 stores an application program 2030. The MCU 2026 is used to execute the application programs 2030. In an embodiment, the application 2030 is responsible for receiving commands from the embedded CPU802 and operating the inverter 1108 accordingly. Application 2030 also sends status information about inverter 1108 to embedded CPU 802.

As also shown in fig. 20, each battery pack 302 includes a battery system controller 414, the battery system controller 414 having a memory 518. Each memory 518 is used to store an application program 2034. Each application 2034 is executed using the MCU 516. The application program 2034 is also responsible for monitoring the cells of each respective battery pack 302 and sending status information about the cells to the embedded CPU 802. The application program 2034 is also responsible for equalizing the voltage and state of charge (SOC) levels of the cells of each respective battery pack 302.

In one embodiment, each application 2034 operates as follows. At power up, the MCU 518 begins executing boot loader software. The boot loader software copies the application from the flash memory to the RAM and the boot loader software starts executing the application. Once the application software is operating normally, the embedded CPU802 queries the battery controller 414 to determine if it contains the appropriate hardware and software versions for the application 2008 that are executing on the embedded CPU 802. If the battery pack controller 414 contains an incompatible hardware version, the battery pack controller is commanded to shut down. If the battery pack controller 414 contains an incompatible or expired software version, the embedded CPU802 provides the correct or updated application to the battery pack controller and the battery pack controller restarts to begin executing new software.

Once the embedded CPU802 determines that the battery pack controller 414 is operating with the correct hardware and software, the embedded CPU802 verifies that the battery pack 414 is operating with the correct configuration data. If the configuration data is incorrect, the embedded CPU802 provides the correct configuration data to the battery pack controller 414, and the battery pack controller 414 saves this data for use during its next boot. Once the embedded CPU802 verifies that the battery pack controller 414 is operating with the correct configuration data, the battery pack controller 414 executes its application software until it is shut down. In one embodiment, the application software includes a main program that runs several processes cyclically at startup. These processes include (but are not limited to): monitoring the course of cell voltage; monitoring the course of the monomer temperature; a process of determining the SOC of each cell; a process of inverter cells; can (canbus) transmission process and can (canbus) reception process. Other processes implemented within the application software include alarm and error recognition processes and processes for obtaining and managing data identified in FIG. 21 that are not covered by one of the above processes.

Through the description herein, other applications described herein with reference to fig. 20 operate in a similar manner, except that the implemented process obtains and manages different data, as will be understood by those skilled in the relevant art. These different data are described in context with reference to other figures.

Fig. 21 is a graph illustrating exemplary data obtained and/or maintained by the battery pack controller 414 of the battery pack 302. As shown in fig. 21, these data include: the SOC of the battery pack and the SOC of each cell; the voltage of the battery pack and the voltage of each cell; the average temperature of the battery pack and the temperature of each cell; the AH dischargeable value of the battery pack and each cell; the battery pack and the WH dischargeable value of each cell; battery pack and capacity of each cell; information about the last calibration discharge of the battery pack; information about the last calibration charge of the battery pack; information about AH and WI-I efficiencies of the battery pack and each cell; and self-discharge information.

Fig. 22A-22B are diagrams illustrating exemplary data obtained and/or maintained by the embedded CPU802 in an embodiment of an electrical energy storage unit 900 according to the present invention. As shown in fig. 22A to 22B, these data include: SOC information about battery 1102 and each battery pack 302; voltage information about battery 1102 and each battery pack 302; temperature information about battery 1102 and each battery pack 302; AH dischargeable information about battery 1102 and each battery pack 302; WH dischargeable information about battery 1102 and each battery pack 302; capacity information about battery 1102 and each battery pack 302; information about the last calibration discharge of battery 1102 and each battery pack 302; information about the last calibrated charge of battery 1102 and each battery pack 302; information about AH and WH efficiencies of battery 1102 and each battery pack 302; and, self-discharge information.

In addition to the data identified in fig. 22A-22B, embedded CPU802 also obtains and maintains data relating to the health or cycle life of battery 1102. These data are identified in fig. 23A to 23B.

In one embodiment, the data shown in fig. 23A-23B represents the number of charge and discharge counts (i.e., counter values), which work as follows. Assume, for example, that the battery is initially at 90% capacitance and that it is discharged to 10% of its capacitance. This discharge represents an 80% capacitance discharge, with the end discharge state being 10% capacitance. Thus, for such discharge, the discharge counter represented by the battery SOC after 10-24% discharge and due to the 76-90% battery capacitance discharge (i.e., the counter having a value of 75 in FIG. 23B) will increment. In a similar manner, after each charge or discharge progression of the battery, the embedded CPU802 determines and increments the appropriate counter. A process implemented in software increments the count value, using different weights for different counter values to determine the effective cycle life of the battery. The exemplary counters identified in fig. 23A-23B are intended to be illustrative and not limiting for purposes of the present invention.

Fig. 24A-24B are graphs showing how calibration, charging and discharging progress of an electrical energy storage unit is controlled according to an embodiment of the invention. As described herein, the battery of an electrical energy storage unit is managed based on a cell voltage level and a cell state of charge (SOC) level.

As shown in FIG. 24A and described below, four high voltage values 2402 (i.e., V)_H1、V_H2、V_H3And V_H4) And four high state of charge values 2406 (i.e., SOC)_H1、SOC_H2、SOC_H3And SOC_H4) For controlling the charging progress. Four low voltage values 2404 (i.e., V)_L1、V_L2、V_L3And V_L4) And four low state of charge values 2408 (i.e., SOC)_L1、SOC_L2、SOC_L3And SOC_L4) For controlling the discharge progress. In an embodiment of the invention, as shown in fig. 2A, the voltages 2410a (represented by X in fig. 24A) for a particular set of cells may all be below V_H1And the SOC value 2410b for some or all of these cells is also at or above SOC_H1The value of (c). Also, as shown in fig. 24B, the voltage 2410c (represented by X in fig. 24B) for the set of cells may also be higher than V_L1And the SOC value 2410d for some or all of these cells is also at or below SOC_L1The value of (c). Thus, as described in greater detail below, all eight voltage values and all eight SOC values are used as described herein to manage the battery of the electrical energy storage unit according to the present invention.

Since the cell voltage value and the cell SOC value are important for the normal operation of the electrical energy storage unit according to the present invention as described herein, it is necessary to periodically calibrate the unit so that it properly determines the voltage level and SOC level of the battery cell. This operation is performed using a calibration procedure implemented in software.

The calibration process is initially performed when a new electrical energy storage unit is first put into use. Ideally, all cells of the electrical energy storage unit cell should be at about the same SOC (e.g., 50%) when the cell is first installed into the electrical energy storage unit. This requires minimizing the amount of time required to complete the initial calibration process. Thereafter, each time the following recalibration trigger is metOne of the standards performs the calibration process: standard 1: a programmable recalibration interval, e.g., six months, has elapsed since the last calibration date; standard 2: the cells are charged and discharged (i.e., cycled) by a programmable weighted number of charge and discharge cycles, such as a weighted equivalent of 150 full charge and full discharge cycles; standard 3: after attempting to equalize the cells, the high and low SOC cells of the electrical energy storage unit cell differ by more than a programmable SOC percentage, e.g., 2-5%; standard 4: during battery charging, a cell arrival value V is detected_H4And one or more of the monomers is below V_H4The case of the voltage of (see fig. 24A) and this case cannot be corrected by the cell equalization; standard 5: during battery discharge, a cell arrival V is detected_L4And one or more of the monomers is at greater than V_L4And this difference is corrected by the cell balancing.

When one of the above recalibration triggering criteria is met, a battery recalibration flag is set by the embedded CPU 802. The first battery charge performed after the battery recalibration flag is set is a charging progression that fully charges all cells of the battery. The purpose of this charging is to bring all cells of the battery into a known full state of charge. After the cell is in this known full state of charge, the battery discharge immediately following is referred to as a calibration discharge. The purpose of the calibration discharge is to determine how much dischargeable ampere-hour of charge is stored in each cell of the battery and how much dischargeable energy is stored in each cell of the battery when fully charged. The charging of the battery after the calibration discharge is referred to as calibration charging. The purpose of the calibration charge is to determine how many amp-hours of charge must be supplied to each cell and how many watt-hours of energy must be supplied to each cell after the calibration discharge so that all cells return to their known condition at the end of full charge. The values determined during implementation of such a calibration process are stored by the embedded CPU802 and used to determine the SOC of the battery cell during normal operation of the electrical energy storage unit.

In one embodiment, the flag is recalibrated in the batteryThe following first charging is performed as follows: step 1: charging cells of the battery at a constant current rate of CAL-I until the first cell of the battery reaches V_H2The voltage of (c). Step 2: once the first cell of the battery reaches V_H2To a value called END-charge-I (END-CHG-I), and to resume charging the cell. And step 3: continuing to charge the battery cells with an END-charge-I (END-CHG-I) current until all cells of the battery attain a voltage at V_H3And V_H4The voltage value in between. And 4, step 4: if any monomer reaches V during step 3_H4Voltage of (c): (a) stopping charging the monomer; (b) for example using inverter resistors to make all voltages higher than V_H3Until the cells have V_H3Voltage of (d); (c) once all cell voltages are at or below V_H3Starting charging the cell again with an END-charge-I (END-CHG-I) current; and (d) looping back to step 3. This procedure, when implemented, charges all cells of the battery to what is known as SOC_H3A known state of charge (e.g., about 98% SOC). In an embodiment, the charge rate (CAL-I) should be about 0.3C and the END-charge-I (END-CHG-I) current should be about 0.02 to 0.05C.

As noted above, the first discharge after the above-described charge is the calibration discharge. In an embodiment, the calibration discharge is performed as follows. Step 1: discharging the cells of the battery at a constant current rate of CAL-I until the first cell of the battery reaches V_L2The voltage of (c). Step 2: once the first cell of the battery reaches V_L2Reducing the cell discharge current to a value referred to as end-discharge-I (e.g., about 0.02-0.05C), and restarting cell discharge. And step 3: continuing to discharge the battery cells with an END-discharge-I (END-DISCHG-I) current until all cells of the battery attain a voltage at V_L3And V_L4The voltage value in between. And 4, step 4: if any monomer reaches V during step 3_L4Voltage of (c): (a) stopping discharging the monomer; (b) for example using inverter resistors to make all voltages higher than V_L3Until the cells have V_L3The voltage of (c). At schoolAt the end of the quasi-discharge, the amp-hours discharged by each cell and the watt-hours discharged by each cell were determined, and these values represented by fig. 21, 22A, and 22B were recorded. As described herein, the purpose of calibration discharge is to determine how many dischargeable amp-hours' ends are stored in each cell and how much dischargeable energy is stored in each cell when fully charged.

After the calibration discharge, the next charge to be performed is referred to as calibration charge. The purpose of the calibration charge is to determine how many amp-hours of charge must be supplied to each cell after the calibration discharge and how many watt-hours of energy must be supplied to each cell to bring all cells back to full charge. This process proceeds as follows: step 1: charging cells of the battery at a constant current rate of CAL-I until the first cell of the battery reaches V_H2Voltage of (d); step 2: once the first cell of the battery reaches V_H2To a value called END-charge-I (END-CHG-I), and to resume charging the cell. And step 3: continuing to charge the battery cells with an END-charge-I (END-CHG-I) current until all cells of the battery attain a voltage at V_H3And V_H4The voltage value in between. And 4, step 4: if any monomer reaches V during step 3_H4Voltage of (c): (a) stopping charging the monomer; (b) for example using inverter resistors to make all voltages higher than V_H3Until the cells have V_H3Voltage of (d); (c) once all cell voltages are at or below V_H3Starting charging the cell again with an END-charge-I (END-CHG-I) current; and (d) looping back to step 3. At the end of the calibration charge, the determined amp hours required to recharge each cell and the determined watt hours required to recharge each cell are recorded as shown in fig. 21, 22A and 22B. By comparing the calibration charging information with the calibration discharging information, the AH efficiency and WH efficiency of the electric energy storage unit can be determined.

In an embodiment of the invention, when the battery of the electrical energy storage unit is charged during normal operation, it is charged using the following charging process.Step 1: commands are received from an authorized user or application running on embedded CPU802 specifying details of charging the electrical energy storage cell. This message may specify, for example, the charging current (CHG-I), the charger power (CHG-P), or the SOC value at which the battery should be charged. The command may also specify a charge start time, a charge stop time, or a charge duration. Step 2: after receiving the command, the command is verified and the charging progress is scheduled according to the specified criteria. And step 3: at the appropriate time, the electric energy storage unit cells are charged according to the prescribed standard as long as no cell reaches more than the SOC_H2And no cell reaches V_H2The voltage of (c). And 4, step 4: if during charging, the cell reaches SOC_H2State of charge or V_H2To a rate no greater than END-charge-I (END-CHG-I), and in one embodiment, the inverter resistors of the cells (i.e., the inverter resistor switches are closed) are employed to limit the rate at which the cells are charged. And 5: after reducing the charge rate in step 4, the charging of the battery cells continues at the reduced charge rate until all cells of the battery have attained at least the SOC_H1SOC or at V_H1And V_H3The voltage value in between. Obtaining SOC at a battery cell_H0Or V_H2Its inverter resistor is used to reduce its charging rate. Step 6: if any cell reaches SOC during step 5_H3State of charge or V_H3Voltage of (c): (a) stopping charging the battery monomer; (b) after stopping charging, has a SOC greater than_H2State of charge of or greater than V_H2Until the cells have an SOC, all cells of the voltage of (1) are discharged using the inverter resistor_H2State of charge or V_H2Voltage of (d); (c) once all cell voltages are at or below SOC_H2And V_H2Starting charging the cell again with an END-charge-I (END-CHG-I) current; and (d) looping back to step 3.

In an embodiment, at the end of the charging process described above, the recalibration criteria are checked to determine whether a calibration process should be carried out. If any of the calibration trigger criteria are met, then a recalibration flag is set by the embedded CPU 802.

In an embodiment of the invention, when the battery of the electrical energy storage unit is discharged during normal operation, it is discharged using the following charging process. Step 1: a command is received specifying details of the discharge of the electrical energy storage cells. Such a command may specify, for example, a discharge current (DISCHG-1), a discharge power (DISCHG-P), or SOC at which the battery should be discharged. The command may also specify a discharge start time, a discharge stop time, or a discharge duration. Step 2: after receiving the command, the command is verified and the discharge progress is scheduled according to the specified criteria. And step 3: at an appropriate time, the electric energy storage unit cells are charged according to the prescribed standard as long as no cell reaches less than the SOC_L2And no cell reaches V_L2The voltage of (c). And 4, step 4: if during discharge, the battery cell reaches SOC_L2State of charge or V_L2To a rate no greater than END-DTSCHG-I, and in one embodiment, the inverter resistor of the cell (i.e., the inverter resistor switch is closed) is employed to limit the rate at which the cell is discharged. And 5: after reducing the charge rate in step 4, the charging of the battery cells continues at the reduced charge rate until all cells of the battery have attained at least the SOC_L1SOC or at V_L1And V_L3The voltage value in between. Step 6: if any cell reaches SOC during step 5_L3State of charge or V_L3Voltage of (c): (a) stopping discharging the battery cells; (b) after stopping discharging, has a value greater than SOC_L1State of charge of or greater than V_L1Until the cells have an SOC, all cells of the voltage of (1) are discharged using the inverter resistor_L1State of charge or V_L1Voltage of (d); (c) at all cell voltages at SOC_L1Or V_L1Thereafter, all inverter switches are turned off and cell discharge is stopped.

At the end of the discharge process, the battery recalibration criteria are checked to determine whether a calibration process should be carried out. If any of the calibration trigger criteria are met, then the battery recalibration flag is set by the embedded CPU 802.

As described herein, the embedded CPU802 and battery pack 302 continuously monitor the voltage level and SOC level of all cells of the ESU battery. If at any time the cell voltage or cell SOC exceeds or falls below a prescribed voltage or SOC safety value (e.g., VH4, SOCH4, VL4, or SOCL4), the embedded CPU802 immediately stops, whatever operation is currently being performed, and appropriately starts the overcharge prevention or overdischarge prevention process as described below.

The overcharge prevention process is implemented, for example, any time the embedded CPU802 detects that the battery cell has a voltage higher than VH4 or a state of charge greater than SOCH 4. In an embodiment, when the overcharge prevention process is implemented, it turns on the grid-connected inverter (if available) and discharges the cells at a current rate called OCP-DISCHG-I (e.g., 5Amps) until all cells of the battery are at or below the state-of-charge level of SOCH3 and at or below the voltage level of VH 3. If a grid connected inverter is not provided to discharge the battery cells, then inverter resistors are used to discharge any cells with a state of charge level greater than SOCH3 or a voltage level greater than VH3 until all cells are at a state of charge level less than or equal to SOCH3 and a voltage level less than or equal to VH 3.

If during operation the embedded CPU802 detects that the cell voltage is less than VL4 or the state of charge is less than SOCL4, the embedded CPU802 will immediately stop the currently performed operation and begin implementing the over-discharge prevention process. The over-discharge prevention process turns on the charger (if available) and charges the battery at a current rate called ODP-CHG-I (e.g., 5Amps) until all cells of the battery are at or above the state-of-charge level SOCL3 and at or above the voltage level of VL 3. If no charger is provided to charge the battery cells, then the individual battery inverter charger is used to charge any cells with a state of charge level below the SOCL3 or a voltage level below VL3 until all cells are at a state of charge level greater than or equal to SOCL3 and a voltage level greater than or equal to VL 3.

As described herein, one of the functions of battery pack 302 is to control the voltage inverter and SOC inverter of its cells. This is achieved using a process implemented in software. In one embodiment, this process is as follows. Embedded CPU802 monitors and maintains a copy of the voltage and SOC information transmitted by battery pack 302. The information is used by the embedded CPU802 to calculate a target SOC value and/or a target voltage value, which is communicated to the battery pack 302. Battery pack 302 then attempts to match the communicated target value to a prescribed tolerance range. As described above, this is accomplished by the battery pack 302 through the use of, for example, an inverter resistor or energy transfer circuit element and an inverter charger.

To more fully understand how to implement an inverter according to an embodiment of the present invention, consider the situation represented by the cell voltage value or cell SOC value 2502a depicted in the upper half of fig. 25. Cell 2504 of battery pack 1(BP-1) is closely centered about the value V/SOC 2. The cells 2506 of battery pack 2(BP-2) are loosely centered about a value between V/SOC2 and V/SOC 3. Cell 2508 of battery pack 3(BP-3) is closely centered about value V/SOC 1. Cell 2510 of battery pack 4(BP-4) is loosely centered about a value between V/SOC2 and V/SOC 3. Assuming that the target value communicated by the embedded CPU802 to the battery pack is the value shown in the bottom half of fig. 25 (i.e., the value between V/SOC2 and V/SOC 3), the following measures are taken by the battery pack to achieve this target value. For battery 1, the battery inverter charger (e.g., ac inverter charger 416) may turn on to add charge to cell 2504 and thus increase its value from the value shown in the upper half of fig. 25 to the value shown in the lower half of fig. 25. For battery pack 2, the battery pack equalization charger may turn on to add charge to cell 2506 while closing the equalization resistors associated with a particular high value cell (thereby passing the charging current), and then turn off the equalization charger while still closing some of the equalization resistors to discharge energy from the highest value cell until cell 2506 achieves the state shown in the lower half of fig. 25. For battery pack 3, the battery pack equalization charger may turn on to add charge to cell 2508 while closing the inverter resistor associated with the particular high value cell (thereby passing the charging current) until cell 2508 achieves the state illustrated in the lower half of fig. 25. For battery pack 4, leveling is not needed because cells 2510 already meet the target value.

Fig. 26A,26B,26C, and 26D are diagrams illustrating an example battery pack 2600 according to another embodiment of the present invention. Specifically, fig. 26A and 26B depict a front view of the battery pack 2600, and fig. 26C depicts an exploded view of the battery pack 2600; and fig. 26D depicts front and side views of the battery pack 2600. As shown in fig. 26A-26D, the housing of the battery pack 2600 can include a front panel 2602, a cover or covering 2612, a back panel 2616, and a bottom 2618. The cover 2612 includes left and right side portions, and the cover 112 may include a plurality of vents to facilitate the passage of air through the battery pack 2600 and to cool the internal components of the battery pack 2600. In a non-limiting embodiment, the cover 2612 is "U" shaped and may be made from a single piece of metal, plastic, or any other material known to one of ordinary skill in the art. The battery packs of fig. 48A-48B (below) may be implemented as described with respect to the battery pack 2600 of fig. 26A-26D.

The housing of the battery pack 2600 may be assembled using fasteners 2628 shown in fig. 26C, which may be screws and bolts or any other fasteners known to one of ordinary skill in the art. The housing of the battery pack 2600 can also include a front handle 2610 and a rear handle 2614. As shown in fig. 26C, the front plate 2602 can be coupled to the cover 2612 and the bottom 2618 via a front plate mount 2620. In one embodiment, battery pack 2600 is implemented as a rack-mountable equipment module. For example, the battery pack 2600 may be implemented as a standard 19 inch rack (e.g., a front panel 2602 having a width of 19 inches, and a battery pack 2600 having a depth of between 22 and 24 inches and a height of four rack units or "U," where U is a standard unit equal to 1.752 inches). As shown in fig. 26C, the battery pack 2600 can include one or more mounts 2622 attached to the bottom 2618. The mounts 2622 may be used to secure the battery pack 2600 in a rack to arrange a plurality of battery packs in a stacked configuration (shown in BESS 4700 of fig. 47).

In fig. 26A-26D, the battery pack 2600 includes a power connector 2604 connectable to a negative terminal of the battery pack and a power connector 2606 connectable to a positive terminal of the battery pack. In other embodiments, power connector 2604 may be used to connect to the positive terminal of a battery pack and power connector 2606 may be used to connect to the negative terminal of a battery pack. As shown in fig. 26A and 26B,

power connectors

2604 and 2606 may be provided on a front panel or face plate 2602 of the battery pack 2600. Electrical cables (not shown) may be attached to the

power connectors

2604 and 2606 and used to add energy to the battery pack 2600 or remove energy from the battery pack 600.

The front panel 2602 of the battery pack 2600 may also include a status light and a reset button 2608. In one embodiment, the status button 2608 is a button that can be pressed to reset or restart the battery pack 2600. In one embodiment, an outer ring around the center of the button 2608 may be illuminated to indicate the operating condition of the battery pack 2600. Such illumination may be generated by a light source, such as one or more light emitting diodes, coupled to or part of the status button 2608. In this embodiment, different colored illumination may indicate different operating states of the battery pack. For example, a constant or steady state green light may indicate that battery pack 2600 is in a normal operating state; flashing or gating a green light may indicate that battery pack 2600 is in a normal operating state and that battery pack 2600 is currently operating the battery inverter; constant or steady state yellow light may indicate a warning or that battery pack 2600 is in an error state; flashing or strobing yellow light may indicate a warning or that battery pack 2600 is in an error state and that battery pack 2600 is currently leaving the battery inverter; a constant or steady state red light may indicate that battery pack 2600 is in an alarm state; flashing or strobing a red light may indicate that the battery pack 2600 needs to be replaced; and no light from the condition light may indicate that battery pack 2600 is not powered and/or needs replacement. In certain embodiments, when the condition light emits red light (steady state or blinking) or no light, the connectors in the battery pack 2600 or external controller automatically disconnect to prevent the battery from charging or discharging. As will be apparent to one of ordinary skill in the art, any color, stroboscopic technique, etc., that lights up to indicate the operating condition of the battery pack 2600 is within the scope of the present invention.

Turning to fig. 26C-26D, example components disposed inside the housing of the battery pack 2600 are shown, including, but not limited to, an equalization charger 2632, a Battery Pack Controller (BPC)2634, and a Battery Module Controller (BMC) 2638. The equalization charger 2632 may be a power source, such as a dc power source, and may provide energy to all cells in the battery pack. In one embodiment, the equalization charger 2632 may provide power to all cells in the battery pack simultaneously. BMC 2638 is coupled to battery module 2636 and may selectively discharge and measure (e.g., voltage and temperature) from the battery cells included in battery module 2636. The BPC 2634 may control the equalization charger 2632 and the BMC 2638 to equalize or adjust the voltage and/or state of charge of the battery modules to target voltage and/or state of charge values.

As shown in fig. 26A-26D, the battery pack 2600 includes a plurality of battery modules and a BMC (e.g., battery module controller 2638) is coupled to each battery module (e.g., battery module 2636). In one embodiment, described in more detail below, n BMCs (where n is greater than or equal to 2) may be daisy-chained together and coupled to the BPC to form a single wire communication network. In this example arrangement, each BMC may have a unique address and the BPC may communicate with each of the BMCs by addressing one or more messages to the unique address of any desired BMC. The one or more messages (which include the unique address of the BMC) may include the following instructions: such as removing energy from the battery module, ceasing to remove energy from the battery module, measuring and reporting the temperature of the battery module, and measuring and reporting the voltage of the battery module. In one embodiment, the BPC 2634 may obtain measurements (e.g., temperature, voltage) from each of the BMCs using a polling technique. The BPC 2634 may calculate or receive a target voltage for the battery pack 2600 (from a controller outside the battery pack 2600), and may adjust each of the battery modules to the target voltage using a network of inverter chargers 2632 and BMCs. Therefore, battery pack 2600 can be considered an intelligent battery pack that is capable of self-regulating its cells to a target voltage.

Electric wiring connecting the respective components of the battery pack 2600 is omitted from the drawing to enhance visibility. However, fig. 26D shows example wiring in the battery pack 2600. In the illustrated 26D embodiment, the inverter charger 2632 and the battery pack controller 2634 may be connected to the bottom portion 2618 or mounted on the bottom portion 2618. Although shown mounted on the left side of the battery pack 2600, the inverter charger 2632 and the battery controller 2634, as well as all other components disposed in the battery pack 2600, may be disposed anywhere within the battery pack 2600.

The battery module 2636 includes a plurality of battery cells. Any number of battery cells may be included in battery module 2636. Example battery cells include, but are not limited to, lithium ion battery cells, such as 18650 or 26650 battery cells. The cells may be cylindrical cells, prismatic cells, or pouch cells, to name a few. The battery cell or battery module may, for example, be up to 100AH battery cells or battery modules. In certain embodiments, the battery cells are connected in a series/parallel configuration. Exemplary battery cell configurations include (but are not limited to): 1P16S configuration, 2P16S configuration, 3P16S configuration, 4P16S configuration, 1P12S configuration, 2P12S configuration, 3P12S configuration, and 4P12S configuration. Other configurations known to those of ordinary skill in the art are also within the scope of the present invention. Battery module 2636 includes positive and negative terminals for adding or removing energy from the plurality of battery cells included therein.

As shown in fig. 26C, the battery pack 2600 includes 12 battery modules forming a battery assembly. In another embodiment, battery pack 2600 includes 16 battery modules forming a battery assembly. In other embodiments, the battery pack 2600 includes 20 battery modules or 25 battery modules forming a battery assembly. As will be apparent to one of ordinary skill in the art, any number of battery modules may be connected to form a battery assembly of the battery pack 2600. In the battery pack 2600, the battery modules arranged as a battery assembly may be arranged in a series configuration.

In fig. 26C, a battery module controller 2638 is coupled to the battery module 2636. The battery module controller 2638 may be coupled to positive and negative terminals of the battery module 2636. The battery module controller 2638 may be configured to perform one, some, or all of the following functions: removing energy from the battery module 2636; measuring the voltage of the battery module 2636; and measuring the temperature of the battery module 2636. As one of ordinary skill in the art will appreciate, the battery module controller 2638 is not limited to performing the functions just described. In an embodiment, battery module controller 2638 is implemented as one or more circuits disposed on a printed circuit board. In battery pack 2600, one battery module controller is coupled to or mounted on each of the battery modules in battery pack 2600. Further, each battery module controller may be coupled to one or more adjacent battery module controllers via wiring to form a communication network. As shown in fig. 27A, n battery module controllers (where n is an integer greater than or equal to two) may be daisy-chained together and coupled to a battery pack controller to form a communication network.

Fig. 27A is a diagram illustrating an example communication network 2700 formed by a battery pack controller and a plurality of battery module controllers according to an embodiment of the present invention. In fig. 27A, a Battery Pack Controller (BPC)2710 is coupled to n Battery Module Controllers (BMCs) 2720, 2730, 2740, 2750, and 2760. In other words, n battery module controllers (where n is an integer greater than or equal to two) are daisy-chained together and coupled to the battery pack controllers 2710 to form the communication network 2700, the communication network 700 is referred to as a distributed daisy-chained Battery Management System (BMS). Specifically, the BPC 2710 is coupled to the BMC 2720 via a communication line 2715, the BMC 2720 is coupled to the BMC 2730 via a communication line 2725, the BMC 2730 is coupled to the BMC 2740 via a communication line 2735, and the BMC 2750 is coupled to the BMC 2760 via a communication line 2755 to form a communication network. Each of the

communication lines

2715, 2725, 2735, and 2755 may be a single line, forming a single wire communication network that allows BCM 2710 to communicate with each of BCMs 720-2760, and vice versa. As will be apparent to one skilled in the art, any number of BMCs may be daisy-chained together in communication system 2700.

Each BMC in communication network 2700 may have a unique address that BCP 2710 uses to communicate with individual BMCs. For example, BMC 2720 may have an address of 0002, BMC 2730 may have an address of 0003, BMC 2740 may have an address of 0004, BMC 2750 may have an address of 0005, and BMC 2760 may have an address of 0006. BPC 2710 may communicate with each of the BMCs by addressing one or more messages to a unique address of any desired BMC. The one or more messages (which include the unique address of the BMC) may include the following instructions: such as removing energy from the battery module, ceasing to remove energy from the battery module, measuring and reporting the temperature of the battery module, and measuring and reporting the voltage of the battery module. The BPC 2710 may poll the BMC to obtain measurements, such as voltage and temperature measurements, regarding the battery modules of the battery pack. Any polling technique known to those skilled in the art may be used. In certain embodiments, the BPC 2710 continuously polls the BMC for measurements to continuously monitor the voltage and temperature of the battery modules in the battery pack.

For example, the BPC 2710 may seek to communicate with the BMC 2740, e.g., to obtain temperature and voltage measurements of a battery module in which the BMC 2740 is installed. In this example, BPC 2710 generates a message and sends a message (or instruction) addressed to BMC 2740 (e.g., address 0004). Other BMCs in the communication network 2700 may decode the address of the message sent by the BPC 2710, but only the BMC with the unique address of the message (in this example, BMC 2740) may respond. In this example, BMC 2740 receives messages from BPC 2710 (e.g., the messages arrive at BMC 2740 via

communication lines

2715, 2725, and 2735), and generates and transmits a response to BPC 2710 via a single wire communication network (e.g., the response arrives at BPC 2710 via

communication lines

2735, 2725, and 2715). BPC 2710 may receive the response and direct BMC 2740 to perform a function (e.g., remove energy from the battery module in which it is installed). In other embodiments, other types of communication networks (other than communication network 2700) may be used. Such as RS232 or RS485 communication networks.

Fig. 27B is a flow diagram of an example method 27000 for receiving instructions at a battery module controller, such as the battery module controller 2638 of fig. 26C or the battery module controller 2720 of fig. 27A. 27A. the battery module controller described with respect to fig. 27B can be included in a communication network that includes more than one isolated, distributed, daisy-chained battery module controller, such as the communication network 2700 of fig. 27A.

The method 27000 of fig. 27B may be implemented as software or firmware executable by a processor. That is, each stage of method 27000 can be implemented as one or more computer readable instructions stored on a non-transitory computer readable storage device, which when executed by a processor, cause the processor to perform one or more operations. For example, method 27000 may be implemented as one or more computer readable instructions stored in and executed by a processor of a battery module controller (e.g., battery module controller 138 of fig. 1C or battery module controller 2720 of fig. 27A) installed on a battery module (e.g., battery module 2636 of fig. 26C) in a battery pack (e.g., battery pack 2600 of fig. 26A-26D).

Since the description of fig. 27B refers to components of the battery pack, the components enumerated in the example embodiment of the battery pack 2600 of fig. 26A-26D and the example communication network of fig. 27A are used to refer to specific components for clarity when describing the different stages of the method 27000 of fig. 27B. However, the battery pack 2600 and communication network 2700 of fig. 26A-26D are examples only, and the method 27000 can be implemented using battery packs other than the example embodiment depicted in fig. 26A-26D and embodiments of the communication network 2700 other than the example embodiment depicted in fig. 27A.

At the start (stage 27100), the method 27000 continues to stage 27200 where the battery module controller receives the message at stage 7020. For example, the battery pack controller may communicate with a network of daisy-chained battery module controllers (e.g., fig. 27A) to inverter the batteries in the battery pack (e.g., 5 battery packs 2600 in fig. 26A-26D). The message may be received at a communication terminal of the battery module controller via a communication line (e.g., 5 communication lines 2715 in fig. 27A). This communication may include, but is not limited to, the network of finger conductive battery module controllers providing voltage and/or temperature measurements of the battery modules to which the battery module controllers are mounted, and the finger conductive battery module controllers removing energy from or ceasing to remove energy from the battery modules to which the battery module controllers are respectively mounted.

As discussed with respect to fig. 27A, each battery module controller (e.g., BMC 2720 of fig. 27A) in a communication network (e.g., communication network 2700 of fig. 27A) may have a unique address, which the battery pack controller (e.g., BPC 2710 of fig. 27A) uses to communicate with the battery module controller. Thus, the message received at stage 27200 may include the address of the battery module controller for which it is intended and the instructions to be executed by the battery module controller. At stage 27300, the battery module controller determines whether the address included in the message matches the unique address of the battery module controller. If the addresses do not match, the method 27000 returns to stage 27200 and the battery module controller waits for a new message. That is, the battery module controller ignores the instruction associated with the message in response to determining that the address associated with the message does not match the unique address of the battery module controller. If the addresses do not match, the method 27000 proceeds to stage 27400.

In stage 27400, the battery module controller decodes the instructions included in the message and the method 27000 proceeds to stage 27500. At stage 27500, the battery module is polled for voltage measurements. Also, the instructions may (but are not limited to) measure and report the temperature of the battery module, measure and report the voltage of the battery module, remove energy from the battery module (e.g., apply one or more shunt resistors across the terminals of the battery module), stop removing energy from the battery module (e.g., stop applying one or more shunt resistors to the terminals of the battery module), or calibrate the voltage measurement prior to measuring the battery voltage. In various embodiments, the temperature and voltage measurements may be sent as actual temperature and voltage values, or as encoded data, which may be decoded after the measurements are reported. After stage 27500, the method 27000 loops back to stage 27200 and the battery module controller waits for a new message.

Fig. 28 is a diagram illustrating an example battery pack controller 2800 according to an embodiment of this disclosure. The battery controller 2634 of fig. 26C and 26D may be implemented as described with respect to the battery controller 2800 of fig. 28. The battery pack controller 2710 of fig. 27A may be implemented as described with respect to the battery pack controller 2800 of fig. 28.

As shown in fig. 28, the example battery pack controller 2800 includes a dc input 2802 (which may be an isolated 5V dc input), a charger switch circuit 2804, a DIP-switch 2806, a JTAG connection 2808, a can (canbus) connection 2810, a microprocessor unit (MCU)2812, a memory 2814, an external EEPROM 2816, a temperature monitoring circuit 2818, a status light and reset button 2820, a watchdog timer 2822, and a Battery Module Controller (BMC) communication connection 2824.

In one embodiment, the battery pack controller 2800 is also powered from the energy in the storage cells. The battery pack controller 2800 may be connected to the battery cells by a dc input 2802. In other embodiments, the battery pack controller 2800 may be powered from an ac to dc power source connected to the dc input 2802. In these embodiments, the dc-dc power supply may then convert the input dc power to one or more power levels suitable for operating the various electrical components of the battery pack controller 2800.

In the exemplary embodiment illustrated in fig. 28, the charger switch circuit 2804 is coupled to the MCU 2812. The charger switch circuit 2804 and MCU 2812 may be used to control the operation of an inverter charger, such as inverter charger 2632 of fig. 26C. As described above, the inverter charger may add energy to the cells of the battery pack. In an embodiment, the temperature monitoring circuit 2818 includes one or more temperature sensors that can monitor the temperature of a heat source within the battery pack, such as the temperature of an inverter charger used to add energy to the cells of the battery pack.

The battery pack controller 2800 may also include several interfaces and/or connectors for communication. These interfaces and/or connectors may be coupled to MCU 2812, as shown in fig. 28. In one embodiment, these interfaces and/or connectors include: a DIP-switch 2806 that may be used to set a portion of the software bits used to identify the battery pack controller 2800; a JTAG connection 2808 that can be used to test and debug the battery pack controller 2800; can (canbus) connection 2810, which may be used to communicate with a controller outside the battery pack; and a BMC communication connection 2824 that may be used to communicate with one or more battery module controllers, such as a distributed daisy-chained network of battery module controllers (e.g., fig. 27A). For example, the battery controller 2800 can be coupled to a communication line, such as the communication line 2715 of fig. 27A, via the BMC communication connection 2824.

The battery pack controller 2800 also includes an external EEPROM 2816. The external EEPROM 2816 may store values of the battery pack, measurement values, and the like. These values, measurements, etc. may persist (i.e., will not be lost due to a loss of power) when the power to the battery pack is shut off. The external EEPROM 2816 may also store executable code or instructions, such as those used to operate the microprocessor unit 2812.

A microprocessor unit (MCU)2812 is coupled to a memory 2814. The MCU 2812 is used to execute an application program for managing a battery pack. As described herein, in one embodiment, the application may perform the following functions (but is not limited to these functions): monitoring the voltage and temperature of the cells of battery pack 2600; a battery cell of the inverter battery pack 2600; monitoring and controlling (if necessary) the temperature of the battery pack 2600; handle communications between the battery pack 2600 and other components of the electrical energy storage system; as well as generate warnings and/or alarms, and take other appropriate action to protect the cells of the battery pack 600.

As described above, the battery pack controller may obtain temperature and voltage measurements from the battery module controller. The temperature readings may be used to ensure that the battery cell is operating within its specified temperature limits and to adjust temperature-related values calculated and/or used by applications executing on the MCU 2812. Also, the voltage readings are used, for example, to ensure that the cells are operating within their specified voltage limits.

The watchdog timer 2822 is used to monitor and ensure proper operation of the battery pack controller 2800. In the event of an unrecoverable error or an unscheduled infinite software loop during operation of the battery controller 2800, the watchdog timer 2822 may reset the battery controller 2800 so that it normally resumes operation. A status light and reset button 2820 may be used to manually reset the battery pack controller 2800. As shown in fig. 28, a status light and reset button 2820 and a watchdog timer 2822 may be coupled to MCU 2812.

Fig. 29 illustrates a diagram of an example battery module controller 2900, according to an embodiment of the invention. The battery controller 2638 of fig. 26C and 26D may be implemented as described with respect to the battery controller 2900 of fig. 29. Each of the

battery module controllers

2720, 2730, 2740, 2750, and 2760 of fig. 27A may be implemented as described with respect to the battery module controller 2900 of fig. 9. The battery module controller 2900 may be mounted on a battery module of the battery pack and may perform the following functions (but is not limited thereto): measuring a voltage of the battery module; measuring a temperature of the battery module; and removing energy (discharging) from the battery module.

In fig. 29, a battery module controller 2900 includes a processor 2905, a voltage reference 2910, one or more voltage test resistors 2915, a power supply 2920, a failsafe circuit 2925, a shunt switch 2930, one or more shunt resistors 2935, a polarity protection circuit 2940, an isolation circuit 2945, and a communication line 2950. The processor 2905 controls the battery module controller 2900. The processor 905 receives power from the battery module to which the battery module controller 900 is mounted via the power supply 2920. The power supply 2920 may be a dc power supply. As shown in fig. 29, a power source 2920 is coupled to the positive terminal of the battery module and provides power to the processor 2905. The processor 2905 is also coupled to the negative terminal of the battery module via a polarity protection circuit 2940, the polarity protection circuit 940 protecting the battery module controller 2900 if the battery module controller is improperly installed on the battery module (e.g., the components of the battery module controller 2900 that were originally coupled to the positive terminal in fig. 29 are improperly coupled to the negative terminal and vice versa).

The battery module controller 2900 may communicate with other components of the battery pack (e.g., a battery pack controller, such as the battery pack controller 2634 of fig. 26C) via communication lines 2950 (which may be a single line). As described with respect to the example communication network of fig. 27A, the communication lines 2950 may also be used to connect the battery module controller 2900 to the battery pack controller and/or one or more other battery module controllers in a daisy-chain manner to form a communication network. The communication lines 2950 may be coupled to the battery pack controller 2900 via communication terminals disposed on the battery pack controller 2900. As such, battery module controller 2900 may send and receive messages (including instructions sent from the battery pack controller) via communication lines 2950. When acting as part of a communication network, the battery module controller 2900 may be assigned a unique network address, which may be stored in a memory device of the processor 2905.

The battery module controller 2900 may be electrically isolated from other components coupled to the communication line (e.g., battery pack controller, other battery module controllers, computing systems external to the battery pack) via isolation circuitry 2945. In FIG. 29, an isolation circuit 2945 is disposed between the communication line 2950 and the processor 2905. Likewise, the communication lines 2950 may be coupled to the battery controller 2900 via communication terminals disposed on the battery controller 2900. This communication terminal may be disposed between the communication line 2950 and the isolation circuit 2945, or may be part of the isolation circuit 2945. The isolation circuit 2945 may capacitively couple the processor 2905 to the communication line 2950 or may provide other forms of electrical isolation known to those skilled in the art.

As explained above, the battery module controller 2900 may measure the voltage of the battery module to which it is mounted. As shown in fig. 29, the processor 2905 is coupled to a voltage test resistor 2915, the voltage test resistor 2915 being coupled to the positive terminal of the battery module. The processor 2905 may measure the voltage across the test resistor 2915 and compare this measured voltage to the voltage reference 2910 to determine the voltage of the battery module. As described with respect to fig. 27A, the battery module controller 2900 may be directed by the battery pack controller to measure the voltage of the battery module. After performing the voltage measurement, processor 2905 may report the voltage measurement to the battery pack controller via communication line 2950.

Battery module controller 2900 may also remove energy from the battery module in which it is installed. As shown in fig. 29, the processor 2905 is coupled to a failsafe circuit 2925, and the failsafe circuit 925 is coupled to a shunt switch 2930. The shunt switch 2930 is also coupled to the negative terminal via a polarity protection circuit 2940. A shunt resistor 2935 is disposed between the positive terminal of the battery module and the shunt switch 2930. In this embodiment, when the shunt switch 2930 is open, the shunt resistor 2935 is not applied to the positive and negative terminals of the battery module, and when the shunt switch 2930 is closed, the shunt resistor 2935 is applied to the positive and negative terminals of the battery module to remove energy from the battery module. The processor 2905 may direct the shunt switch 2930 to selectively apply the resistor 2935 to the positive and negative terminals of the battery module in order to remove energy from the battery module. In one embodiment, the processor 2905 directs the shunt switch 2930 to apply the shunt resistor 2935 at regular intervals (e.g., once every 30 seconds) to continuously discharge the battery module.

The failsafe circuit 2925 may prevent the shunt switch 2930 from removing too much energy from the battery module. In the event of a failure of the processor 2905, the failsafe circuit 2925 may direct the shunt switch 2930 to stop applying the shunt resistor 835 to the positive and negative terminals of the battery module. For example, the processor 2905 directs the shunt switch 2930 to apply the shunt resistor 2935 at regular intervals (e.g., once every 30 seconds) in order to continuously discharge the battery module. A failsafe circuit 2925 disposed between the processor 2905 and the shunt switch 2930 may monitor the instructions sent by the processor 2905 to the shunt switch 2930. In the event that the processor 2905 fails to send a scheduling instruction to the shunt switch 2930 (which may be due to a failure of the processor 2905), the failsafe circuit 2925 may direct or cause the shunt switch 2930 to open, preventing further discharge of the battery module. The processor 2905 may direct the failsafe circuit 2925 to prevent the shunt switch 2930 from discharging the battery module below a threshold voltage or state of charge level, which may be stored or calculated in the battery module controller 2900 or an external controller (e.g., battery pack controller).

The battery module controller 2900 of fig. 29 also includes a temperature sensor 2955, and a temperature sensor 955 may measure the temperature of the battery module to which the battery module controller 2900 is connected. As depicted in fig. 29, a temperature sensor 2955 is coupled to the processor 2905 and can provide temperature measurements to the processor 2905. Any temperature sensor known to those skilled in the art may be used to implement temperature sensor 2955.

Example string controller

Fig. 30 is a diagram showing an example string controller 3000. In particular, fig. 30 illustrates example components of the string controller 3000. The example components depicted in fig. 30 may be used to implement the disclosed string controller 4804 of fig. 48A. The string controller 3000 includes a string control board 3024, and the string control board 1124 controls the overall operation of the string controller 3000. The string control board may be implemented as one or more circuits or integrated circuits mounted on a printed circuit board (e.g., string control board 3130 of fig. 31A). The string control board 3024 may include or be implemented as a processing unit, such as a microprocessor unit (MCU)3025, a memory 3027, and executable code. The

units

3026, 3028, 3030, and 3042 shown in the string control board 3024 may be implemented in hardware, software, or a combination of hardware and software. The

units

3026, 3028, 3030, 3032, and 3042 may be individual circuits mounted on a printed circuit board or on a single integrated circuit.

The functions performed by the string controller 3000 may include (but are not limited to) the following: sending a battery string contactor control command, and measuring the voltage of the battery string; measuring a battery string current; calculating the ampere hour count of the battery string; relaying queries between the system controller (e.g., at a charging station) and the battery pack controller; processing the inquiry response message; collecting battery string data; performing a software device ID assignment to the battery pack; detecting a ground fault current in the battery string; and alarm and warning conditions are detected and appropriate corrective action is taken. The MCU 3025 may perform these functions by executing code stored in the memory 3027.

The string controller 3000 includes

battery string terminals

3002 and 3004 to be coupled to positive and negative terminals, respectively, of a battery string (also referred to as a string of battery packs). The

battery string terminals

3002 and 3004 are coupled to a voltage sensing unit 3042 on the string control board 3024, which voltage sensing unit 1142 may be used to measure the battery string voltage.

The string controller 3000 also includes Power Control System (PCS)

terminals

3006 and 3008 coupled to positive and negative terminals, respectively, of a PCS. As shown in fig. 30, the positive battery string terminal 3002 is coupled to the positive PCS terminal 3006 via the contactor 3016 and the negative battery string terminal 3004 is coupled to the negative PCS terminal 3008 via the contactor 3018. The string control board 3024 is coupled to the negative PCS terminal 1108 via

contactor control units

3026 and 3030, respectively. String control board 1124 controls contactors 3016 and 3018 (to open and close) via contactor control units 1126 and 1130, respectively, allowing the battery string to provide energy (discharge) to the PCS or receive energy (charge) from the PCS when

contactors

3016 and 3018 are closed.

Fuses

3012 and 3014 protect the battery string from excessive current flow.

The string controller 3000 also includes

communication terminals

3010 and 3012 for coupling to other devices. In an embodiment, the communication terminal 3010 may couple the string controller 3000 to a battery pack controller of a battery string, allowing the string controller 3000 to issue queries, instructions, and the like. For example, the string controller 3000 may issue commands for the cell inverters from the battery pack. In an embodiment, the communication terminal 3012 may couple the string controller 3000 to an array controller, such as the array controller 4808 of fig. 48A. The

communication terminals

3010 and 3012 may allow the string controller 3000 to relay queries between an array controller (e.g., the array controller 4808 of fig. 48A) and a battery pack controller, aggregate battery string data, perform software device ID assignments to battery packs, detect alarm and warning conditions and take appropriate corrective action, among other functions. In systems that do not include an array controller, a string controller may be coupled to the system controller.

The string controller 3000 includes a power supply unit 3022. The power supply 3120 of fig. 31A may be implemented as described with respect to the power supply unit 3022 of fig. 30. In this embodiment, the power supply unit 3022 may provide more than one dc supply voltage. For example, the power supply unit 3022 may provide one power supply voltage to the power string control board 3024 and another power supply voltage to operate the

contactors

3016 and 3018. In one embodiment, a +5V dc power supply may be used for string control board 3022, and a +12V dc may be used to close

contactors

3016 and 3018.

The string control board 3024 includes a current sensing unit 3028, the current sensing unit 3028 receiving input from a current sensor 3020, the current sensor 3020 may allow the string controller to measure the battery string current, calculate the battery string amp-hour count, and other functions. In addition, the current sensing unit 3028 may provide an input for overcurrent protection. For example, if an overcurrent (current level higher than a predetermined threshold) is sensed by the current sensor 3020, the current sensor unit 3028 may provide a value to the MCU 3025 that directs the

contactor control units

3026 and 3030 to open the

contactors

3016 and 3018, respectively, cutting off the battery string from the PCS. Likewise, fuses 3012 and 3014 may also provide overcurrent protection, disconnecting the battery from the PCS when a threshold current is exceeded.

The string controller 3000 includes battery voltage and ground fault detection (e.g., battery voltage and ground fault detection 3110 of fig. 31A).

Terminals

3038 and 3040 may couple the string controller 3000 to a battery pack in the middle of a battery pack string. For example, in a string of 22 battery packs, terminal 3038 may be connected to the negative terminal of battery pack 11 and terminal 3040 may be connected to the positive terminal of battery pack 12. Considering fig. 48B, SC1 may be coupled to BP11 and BP12 via

terminals

3038 and 3040. The ground fault detection unit 3032 measures the voltage in the middle of the battery string using a resistor 3034 and provides ground fault protection. Fuse 3036 provides overcurrent protection.

Fig. 31A to 31B are diagrams illustrating an example string controller 3100. As shown in fig. 31A, the string controller 3100 holds a battery voltage and ground fault detection unit 3110, a power source 3120, a string control board 3130, a positive fuse 3140, and a positive contactor 3150. Fig. 31B illustrates another angle of the string controller 3100 and depicts a negative fuse 3160, a negative contactor 3170, and a current sensor 3180. These components are described in more detail below with respect to fig. 30.

Example Battery inverter Algorithm

Fig. 32 is a diagram illustrating (demonstrating) an example method 3200 for an inverter battery pack, such as the battery pack 2600 of fig. 26A-26D, the battery pack 2600 including a network of a plurality of battery modules, inverter chargers, battery pack controllers, and isolated, distributed daisy-chain battery module controllers. The method 3200 may be implemented as software or firmware executable by a processor. That is, each stage of method 3200 may be implemented as one or more computer readable instructions stored on a non-transitory computer readable storage device, which when executed by a processor, cause the processor to perform one or more operations. For example, the method 3200 may be implemented as one or more computer readable instructions stored and executed in a battery controller (e.g., the battery controller 2634 of fig. 26C) stored in a battery pack (e.g., the battery pack 2600 of fig. 26A-26D).

Since the description of fig. 32 refers to components of a battery pack, for clarity, examples of component diagrams enumerated in the example embodiment of battery pack 2600 of fig. 26A-26D are used to refer to specific components when describing different stages of method 3200 of fig. 32. However, the battery pack 2600 of fig. 26A-26D is merely an example, and the method 3200 may be implemented using embodiments of the battery pack that are not the exemplary embodiment depicted in fig. 26A-26D.

At the start, method 3200 proceeds to stage 3210 where the target voltage value is received by a battery controller, such as battery controller 2634, at stage 1310. The target value may be for the voltage and/or state of charge of each battery module (e.g., battery module 2636) in the inverter battery pack and may be received from an external controller, such as the string controller described with respect to fig. 48A or 31A-31B. At stage 3215, the battery module is polled for voltage measurements. For example, the battery pack controller 2634 may request voltage measurement values from each of the battery module controllers (e.g., the battery module controllers 2638) mounted to the battery modules. Also, one battery module controller may be mounted on each of the battery modules. Each battery module controller may measure the voltage of the battery module in which the battery module controller is installed and communicate the measured voltage to the battery pack controller 2634. Also, as discussed with respect to fig. 27A, the battery pack controller and the plurality of isolated, distributed daisy-chained battery module controllers may be coupled together to form a communication network. Polling may be performed sequentially (e.g., polling BMC 2720, then BMC 2730, then BMC 2740, and so on). In an embodiment, the target charge value state may be received at stage 3210 instead of the target voltage value.

At stage 3220, a determination is made as to whether each polled battery module voltage is within an acceptable range. This acceptable range may be determined by one or more threshold voltages above and/or below the received target voltage. For example, the battery pack controller 2634 may use a start discharge value, a stop discharge value, a start charge value, and a stop voltage value, which are used to determine whether an inverter of the battery module should be executed. In an embodiment, the start discharge value may be greater than the stop discharge value (both may be greater than the target value) and the start charge value may be less than the stop charge value (both may be less than the target value). These thresholds may be derived by adding a stored offset value to the received target voltage value. In an embodiment, the acceptable range may be between a start discharge value and a start charge value, indicating a range where the inverter may not be needed. If all battery module voltages are within the acceptable range, method 3200 continues to stage 3225. At stage 3225, the inverter charger (e.g., inverter charger 2632) switches off (if on) and the shunt resistor of each battery module controller 2638 that has been applied, such as shunt resistor 2935 of fig. 29, switches off to stop removing energy from the battery module. For example, the battery pack controller 2634 may direct the inverter charger 2632 to stop providing energy to the battery modules of the battery pack 2600. The battery pack controller 2634 may also direct each battery module controller (each battery module controller applies a shunt resistor to its installed battery module) to stop applying shunt resistors and thus remove energy from the battery module. Method 3200 then returns to step 3215 where the voltage values are again polled for the battery modules of the battery pack.

Returning to stage 3220, if all of the battery module voltages are not within the acceptable range, the methods continue to stage 3230. At stage 3230, for each battery module, it is determined whether the battery module voltage is above a start discharge value. If the voltage is above the start discharge value, method 3200 continues to stage 3235 where, at stage 1335, a shunt resistor coupled to a battery module controller (e.g., battery module controller 2638) of the battery module is applied to remove (dump) energy from the module. The method then continues to stage 3240.

At stage 3240, for each battery module, it is determined whether the battery module voltage is above a start discharge value. If the voltage is below the stop discharge value, method 3200 continues to stage 3245 where the shunt resistor of the battery module controller (e.g., battery module controller 2638) coupled to the battery module is disconnected to stop discharging the slave module. That is, the battery module controller stops the application of the shunt resistor(s) to the terminals of the battery module to which it is mounted. This prevents the battery module controller from removing energy from the battery module. The method then continues to stage 3250.

At stage 3250, it is determined that at least one battery module voltage is below a discharge start value. If any voltage is below the start charge value, method 3200 continues to stage 3255, where at stage 1355 the inverter charger is turned on to provide energy to all battery modules. For example, the battery pack controller 2634 may direct the inverter charger 2632 to turn on, providing energy to each of the battery modules of the battery pack 2600. Method 3200 then continues to stage 3260.

At stage 3260, it is determined that all battery module voltages are above the stop charge value. If all voltages are above the stop charge value, method 3200 continues to stage 3265 where the inverter charger is turned off (if previously turned on) to stop charging the battery modules of the battery pack. For example, the battery pack controller 2634 may direct the inverter charger 2632 to stop providing energy to the battery modules of the battery pack 2600. Method 3200 then returns to stage 3215 where the voltage measurements are again polled from the battery modules at stage 1315. Accordingly, as previously described, stages 3215-3260 of method 3200 may continuously inverter energy of a battery pack, such as battery modules within battery pack 2600.

Although the inverter example discussed above only discusses four battery packs for the inverter, the inverter process may be applied to any number of battery packs for the inverter. Also, since this process can be applied to the SOC value as well as the voltage value, this process can be carried out at any time in the electric energy storage unit according to the present invention, and is not limited to the time period when the battery of the electric energy storage unit is charged or discharged.

Example warranty tracker for battery packs

In an embodiment, warranty based on battery usage of a battery pack, such as battery pack 2600 of fig. 26A-26D, may take into account various data associated with the battery pack, such as (but not limited to) charge and discharge rates, battery temperature, and battery voltage. As will be apparent to those skilled in the art, the warranty tracker disclosed below may be implemented and adapted for use in the systems and methods described above. A warranty tracker embedded in the battery pack may use this data to calculate a warranty value indicating that the battery has been in use for a period of time. The calculated warranty values may be aggregated over the life of the battery, and the cumulative value may be used to determine a warranty range. With this solution, the warranty can take into account not only the total discharge of the battery, but also the way the battery is used. Various data used to calculate the warranty value are further discussed with respect to fig. 33, 36A-36B, according to an embodiment.

The charge and discharge rates of the battery pack are related to and can be approximated or determined based on the amount of current flowing in and out of the battery pack, which can be measured. Generally, higher charge and discharge rates may generate more heat (more than lower rates), which may cause stress on the battery pack, shorten the life of the battery pack, and/or cause unexpected failures or other problems. FIG. 33 is a graph illustrating an example correlation between current measurements and current coefficients used to calculate a warranty value, according to an embodiment. For battery packs, such as battery pack 2600 of fig. 26A-26D, the current may be measured directly, and the charge and/or discharge rate of the battery pack may be provided.

The normal charge and discharge rates of batteries of different capacities may vary. Thus, in one embodiment, the current measurements may be normalized to take advantage of the normal charge and discharge rates of the different battery packs. Those skilled in the art will recognize that the measured current may be normalized based on the capacity of the battery pack, resulting in a charge rate. As an example, a normalized discharge rate of 1C will deliver a battery rated capacity in one hour, e.g., a 1,000mAh battery will provide a 1,000mA discharge current for one hour. The charge rate may allow the same criteria to be used to determine normal charge and discharge, whether the battery is rated at 1,000mAh or 100Ah, or any other rating known to those of ordinary skill in the art.

Still considering fig. 33, an example curve 3302 illustrates a current coefficient 3306 as a function of normalized charge rate 3304, according to an embodiment. The current measurement can be used to calculate a quality assurance value by converting the measured current to a corresponding current coefficient. In one embodiment, the measurement current is first normalized to produce a charging rate. The charge rate indicates the charge or discharge rate of the battery pack and allows for consistent warranty calculations regardless of the capacity of the battery pack. The charge rate may then be mapped to a current coefficient for warranty calculations. For example, the normalized charge rate of fig. 1C may be mapped to a current coefficient of 2, while the charge rate of 3C may be mapped to a current coefficient of 10, indicating a higher charge or discharge rate. In an embodiment, separate mapping sets may be maintained for charge and discharge rates. In one embodiment, these mappings may be stored in a look-up table that resides in a computer readable storage device within the battery pack. In another embodiment, the map and current coefficients may be stored in a computer readable storage device external to the battery pack. Alternatively, in one embodiment, rather than explicitly storing the mapping and current coefficients, a predefined mathematical function may be mapped to the charge rate or current measurement to produce a corresponding current coefficient.

In one embodiment, a calculated charge rate above the maximum charge rate warranty threshold 3308 may immediately disable the warranty of the battery pack. This threshold may be predefined or dynamically set by the warranty tracker. In a non-limiting example, the maximum warranty threshold 3308 may be set to a 2C charge rate. A calculated charge rate above the maximum warranty threshold 3308 may indicate that the battery pack is being used improperly, and thus the warranty may not cover the resulting problem. In an embodiment, a maximum warranty threshold may be defined for the charge rate and discharge rate of the battery pack, rather than maintaining a single threshold for both charging and discharging.

Temperature is another factor that may affect battery performance. In general, higher temperatures may cause the battery pack to age at a faster rate due to the generation of higher internal temperatures that cause increased stress on the battery pack. This may shorten the life of the battery pack. On the other hand, lower temperatures may cause damage when charging the battery pack.

FIG. 34 is a graph illustrating an example correlation between temperature measurements and temperature coefficients used to calculate a warranty value, according to an embodiment. Battery packs, such as battery pack 2600 of fig. 26A-26D, may include one or more battery temperature measurement circuits that measure the temperature of individual cells or individual battery modules within the battery pack. The example curve 3402 illustrates a temperature coefficient 3406 as a function of a measured temperature 3404 according to an embodiment. The temperature measurements can be used to calculate a warranty value by converting the measured temperature into a corresponding temperature coefficient. In one embodiment, the temperature measurements may be mapped to temperature coefficients for warranty calculations. For example, a normal operating temperature of 20 ℃ may map to a temperature coefficient of 1, while a higher temperature of 40 ℃ will map to a higher temperature coefficient. A higher temperature coefficient may indicate that battery depletion is occurring at a faster rate. In one embodiment, these mappings may be stored in a look-up table that resides in a computer readable storage device within the battery pack. In another embodiment, the map and temperature coefficients may be stored in a computer readable storage device external to the battery pack. Alternatively, in one embodiment, rather than explicitly storing the map and temperature coefficients, a predefined mathematical function may be applied to the temperature measurements to generate corresponding temperature coefficients.

The warranty threshold may also be a function of the battery temperature, such as charging the battery pack when the temperature is below a predefined value. In an embodiment, operating temperatures below the minimum temperature warranty threshold 3408 or above the maximum temperature warranty threshold 3410 may immediately disable the warranty of the battery pack. These thresholds may be predefined or dynamically set by the warranty tracker. A calculated operating temperature below the minimum warranty threshold 3408 or above the maximum warranty threshold 3410 may indicate that the battery pack is being used improperly, and thus the warranty may not cover the resulting problem. In one embodiment, maximum and minimum warranty thresholds for charging and discharging of the battery pack may be defined, rather than maintaining the same thresholds for charging and discharging.

Voltage and/or state of charge are additional factors that may affect battery performance. The voltage of the battery pack (which may be measured) may be used to calculate or otherwise determine the state of charge of the battery pack. Generally, a very high or very low state of charge or voltage causes increased stress on the battery pack. Which shortens the life span of the battery pack.

FIG. 35 is a graph illustrating an example correlation between voltage measurements and voltage coefficients used to calculate a warranty value, according to an embodiment. Battery packs, such as battery pack 2600 of fig. 26A-26D, may include one or more cell voltage measurement circuits that measure the voltage of individual cells or the voltage of battery modules within the battery pack. These voltage measurements may be aggregated or averaged for use in calculating a warranty value for the battery pack. In one embodiment, the state of charge of the battery pack may be calculated and used to calculate a warranty value; however, such calculations are not always accurate and warranty calculation coefficients must be determined with care. In an embodiment, the measured voltage of the battery pack may be an average measured voltage of each battery cell or each battery module included in the battery pack.

In fig. 35, an example curve 3502 illustrates a voltage coefficient 3506 as a function of a measured voltage 3504 according to an embodiment. By converting the measured voltage into a corresponding voltage coefficient, the voltage measurement can be used to calculate a quality assurance value. In one embodiment, the voltage measurements may be mapped to voltage coefficients for warranty calculations. These maps may be specific to the particular type of battery contained in the battery pack. For example, a battery pack including one or more lithium ion battery cells may have an average cell with a voltage measurement of 3.2V, and a voltage measurement of 3.2V may be mapped to a voltage coefficient of 1. In contrast, voltage measurements at 3.6V or 2.8V can be mapped to higher voltage coefficients. In one embodiment, these mappings may be stored in a look-up table that resides in a computer readable storage device within the battery pack. In another embodiment, the map and voltage coefficients may be stored in a computer readable storage device external to the battery pack. Alternatively, in an embodiment, rather than explicitly storing the map and voltage coefficients, a predefined mathematical function may be applied to the voltage measurements to produce corresponding voltage coefficients.

In one embodiment, a measured voltage below the minimum voltage warranty threshold 3508 or above the maximum voltage warranty threshold 3510 may immediately disable the warranty of the battery pack. These thresholds may be predefined or dynamically set by the warranty tracker. In a non-limiting example, minimum warranty threshold 3508 and maximum warranty threshold 3510 may be set to indicate overdischarge and overcharge of the battery cells, respectively. A measured voltage below minimum warranty threshold 3508 or above maximum warranty threshold 3510 may indicate that the battery pack is being used improperly, and thus the warranty may not cover the resulting problem.

Fig. 36A is a graph illustrating how a battery endurance value 3650 is determined according to an embodiment. This value is also used to determine when the battery warranty fails. As shown in fig. 36A, battery life 3650 at time (T +1) is equal to the product of the battery life value at time (T) and the current factor at time (T) (CF)_(T)) Voltage factor product (VF) at (T)_(T)) And in (T) (TF)_(T)) Temperature factor product (TF)_(T)) In addition, in one embodiment, the battery life value 3650 is generated by the battery life monitor 162 of the battery pack operating system 150.

FIG. 36B is a diagram illustrating example warranty thresholds for defeating the warranty of a battery pack according to an embodiment. As previously mentioned, improper use of the battery pack can cause the warranty to automatically fail. For example, extreme operating temperatures, voltages, or charge/discharge rates may cause the warranty to fail immediately.

In various embodiments, the battery pack may store a minimum recorded voltage 3601, a maximum recorded voltage 3602, a minimum recorded temperature 3603, a maximum recorded temperature 3604, a maximum recorded charge current 3605, and a maximum recorded discharge current 3606 over the life of the battery pack. These values may be recorded by any device or combination of devices capable of measuring or calculating the aforementioned data, such as, but not limited to, one or more battery voltage measurement circuits, battery temperature measurement circuits, and current measurement circuits, respectively, as will be further described with respect to fig. 35, 36A-36B. In an alternative embodiment, the battery pack may record the maximum current in the computer readable storage device instead of the maximum charge and discharge current. In one embodiment, the data measurements may be recorded periodically during the life of the battery in a computer readable storage device. For

minimums

3601 and 3603, if the newly recorded value is less than the stored minimums, then the previously stored value is overwritten by the newly recorded value. For

maxima

3602, 3604, 3605, and 3606, if the newly recorded value is greater than the stored minimum, then the previously stored value is overwritten by the newly recorded value.

In one embodiment, each battery pack may maintain a list of warranty thresholds, e.g.,

thresholds

3611 and 3616, in a computer readable storage device. In another embodiment, the list of warranty thresholds may be maintained in a computer-readable storage device external to the battery pack. The warranty threshold may indicate a minimum and maximum limit for determining the use of battery packs outside of the warranty range. The warranty tracker may periodically compare the minimum and maximum values 3601-.

In one embodiment, the battery pack may store the warranty status in a computer readable storage device. The warranty condition may be any type of data that can represent a condition. For example, the warranty condition may be a binary flag that determines whether the warranty is invalid. The warranty condition may also be, for example, an enumerated type having a set of possible values, such as, but not limited to, valid, expired, and invalid.

As shown in fig. 36B, the warranty conditions are set based on the comparison between the recorded minimum and maximum values 3601-. For example, minimum recording voltage 3601 is 1.6V and minimum voltage threshold 3611 is 2.0V. In this example, minimum recording voltage 3601 is less than minimum voltage threshold 3611 and, therefore, warranty fails, as shown in block 3621. This will be reflected in the warranty status and stored. In various embodiments, when the warranty fails, an electronic communication may be generated and transmitted by the battery pack and/or system, wherein the battery pack is used to notify the selected individual that the warranty has failed. The electronic communication may also include details regarding the conditions or use that caused the warranty to fail.

Fig. 37 is a diagram showing an example use of a battery pack according to an embodiment. In addition to recording the minimum and maximum data values as described with respect to fig. 36, usage frequency statistics may also be collected. For example, usage statistics may be recorded based on battery voltage measurements, battery temperature measurements charge/discharge current measurements, and power calculations (e.g., voltage measurements multiplied by current measurements).

In one embodiment, one or more value ranges may be defined for each type of logging data. In the example shown in FIG. 37, the defined measurement voltage ranges are 2.0V-2.2V, 2.2V-2.4V, 2.4V-2.6V, 2.6V-2.8V, 2.8V-3.0V, 3.0V-3.2V, 3.2V-3.3V, 3.3V-3.4V, 3.4V-3.5V, 3.5V-3.6V, and 3.6V-3.7V. These ranges may be common to lithium ion batteries, for example, in order to capture typical voltages associated with these batteries. Each defined range may be associated with a counter. In one embodiment, each counter is stored in a computer readable storage device within the battery pack. In other embodiments, the counter may be stored external to the battery pack, such as in a string controller, array controller, or system controller of the electrical storage unit (e.g., see fig. 48A). This may allow usage statistics to be further aggregated across multiple battery packs.

In one embodiment, voltage measurements may be taken periodically. When the measured value is within a defined range, the associated counter may be incremented. The value of each counter then represents a measurement frequency that falls within the associated range of values. Frequency statistics are then used to create a histogram that shows the distribution of usage measurements over the life of the battery pack or over a period of time. Likewise, frequency statistics may be recorded for other measurements or calculated data, such as (but not limited to) battery temperature measurements and charge/discharge current measurements.

For example, battery usage 3702 represents a distribution of voltage measurements made during the life of the battery pack. Battery usage 3702 may indicate ordinary or normal use of the battery pack with the highest measurement frequency between 3.0V and 3.2V. In contrast, battery usage 3704 may indicate a more adverse usage.

Histograms, such as those shown in fig. 37, may be suitable for a manufacturer or vendor to determine the extent of improper or uncovered use of the battery pack. In one embodiment, the profile data may also be used to analyze and diagnose battery pack defects and warranty claims.

FIG. 38 is a diagram illustrating an example warranty tracker, according to an embodiment. Warranty tracker 3810 includes a processor 3812, a memory 3814, a battery voltage measurement circuit 3816, and a battery temperature measurement circuit 3818. The battery voltage measurement circuit 3816 and the battery temperature measurement circuit 3818 may be implemented as a single circuit or separate circuits disposed on a printed circuit board. In certain embodiments, such as those described in detail above, each battery module disposed in the battery pack may be coupled to a battery module controller that includes a battery voltage measurement circuit and a battery temperature measurement circuit. In these embodiments, the processor 3812 and memory 3814 of the example warranty tracker 3810 may be part of or implemented within a battery pack controller (such as the battery pack controller 2800 of fig. 28). For example, the warranty tracker may be implemented as executable code in memory 2814 that is executed by MCU 2812 of battery pack controller 2800 to provide the functionality of the warranty tracker.

In various embodiments, the voltage may be measured as an aggregate voltage or an average voltage of the battery cells or battery modules included in the battery pack. The battery temperature measurement circuitry 3818 may include one or more temperature sensors to periodically measure the cell temperature or battery module temperature within the battery pack and send aggregate or average temperature measurements to the processor 3812.

In one embodiment, the processor 3812 also receives periodic current measurements from the battery current measurement circuit 3822. The battery current measurement circuit 3822 may be external to the warranty tracker 3810. For example, the battery current measurement circuit 3822 may reside within a string controller 3820 (e.g., the string controller 3000 of fig. 30). In another embodiment, the battery current measurement circuit 3822 may be part of the warranty tracker 3810.

Processor 3812 may calculate a warranty value based on the received voltage, temperature, and current measurements. In one embodiment, each warranty value represents battery usage when the received measurements are recorded. Once received, the measurements may be converted into associated coefficients for computing a warranty value. For example, voltage measurements received from the battery voltage measurement circuit 3816 may be converted to corresponding voltage coefficients, as described with respect to fig. 35. Likewise, the received temperature measurements and current measurements may be converted to corresponding temperature and current coefficients, as described with respect to fig. 33 and 34.

In one embodiment, processor 3812 may calculate the warranty value by multiplying the voltage coefficient, the temperature coefficient, and the current coefficient together. For example, the current coefficient may be 0 when the battery pack is not charged and is not discharged. The calculated warranty value will therefore also be 0, indicating that no use has occurred. In another example, when the battery temperature and voltage are at optimal levels, the corresponding temperature and voltage coefficients may be 1. The calculated warranty value will then be equal to the current coefficient corresponding to the measured current. When all coefficients are greater than zero, the warranty value indicates battery usage based on voltage, temperature, and current measurements.

As previously described, additional measurements or calculated data may also be used to calculate the warranty value. According to an embodiment, the warranty value may also be calculated based on any combination of voltage, temperature, and current coefficients.

While the warranty value represents battery usage at a point in time, the warranty of a battery pack is based on battery usage over the life of the battery pack (which may be defined by the manufacturer of the battery pack). In one embodiment, the memory 3814 stores a cumulative warranty value, which is indicative of the life of the battery pack. Each time a warranty value is calculated, processor 3812 may add the warranty value to the cumulative warranty value stored in memory 3814. The accumulated warranty value is then used to determine whether the battery warranty value is valid or expired.

FIG. 39 is an example method to calculate and store a cumulative warranty value according to one embodiment. Each stage of the example method may represent computer readable instructions stored on a computer readable storage device, the computer readable instructions being executable by a processor to cause the processor to perform one or more operations.

Method 3900 begins at stage 3904 with measuring a cell voltage within a battery pack. In an embodiment, cell voltage measurements for different cells or battery modules may be aggregated or averaged over the battery pack. At stage 3906, a cell temperature may be measured. In an embodiment, cell temperature measurements for different cells or battery modules may be aggregated or averaged over the battery pack. At stage 3908, charge/discharge current measurements may be received.

Stages

3904, 3906, and 3908 can be performed simultaneously or in any order.

At stage 3910, a warranty value is calculated using the measured battery voltage, the measured battery temperature, and the received current measurement. In one embodiment, each warranty value represents battery usage when the received measurement value is logged. Once received, the measurements may be converted into associated coefficients for computing a warranty value. For example, the voltage measurements may be converted to corresponding voltage coefficients as described with respect to fig. 35. Likewise, the received temperature measurements and current measurements may be converted to corresponding temperature and current coefficients, as described with respect to fig. 33 and 34.

In one embodiment, the warranty value may be calculated by multiplying the voltage coefficient, the temperature coefficient, and the current coefficient together. For example, the current coefficient may be 0 when the battery pack is not charged and is not discharged. The calculated warranty value will therefore also be 0, indicating that no use has occurred. In another example, when the battery temperature and voltage are at optimal levels, the corresponding temperature and voltage coefficients may be 1. The calculated warranty value will then be equal to the current coefficient corresponding to the measured current. When all coefficients are greater than zero, the warranty value indicates battery usage based on voltage, temperature, and current measurements.

At stage 3912, the calculated warranty value is added to the stored cumulative warranty value. In one embodiment, the accumulated warranty value may be stored in the battery pack. In other embodiments, the accumulated warranty value may be stored outside of the battery pack. The accumulated warranty value may then be used to determine that the battery warranty is valid or expired, as will be discussed further below with respect to fig. 40 and 41.

FIG. 40 is an example method of using a warranty tracker according to an embodiment. Fig. 40 may be performed by a computer or human operator at an energy management system, such as an energy management system. Fig. 40 begins at stage 4002 when a warning or alarm is received indicating that the battery pack has an operational problem or is otherwise defective. In one embodiment, the alert may be issued as an email or other electronic communication to an operator responsible for monitoring the battery pack. In other embodiments, the warning or alarm may be an audible or visual alarm, such as a flashing red light on a defective battery pack, such as the warning described above with respect to the status buttons 2608 of fig. 26A and 26B.

In stage 4004, the accumulated warranty value stored in the defective battery pack is compared to a predefined threshold. This threshold may be set to provide a particular warranty period based on normal use of the battery pack. For example, the threshold value may be set so that the battery pack can cover a 10-year warranty based on normal use. In this manner, aggressive use of the battery may reduce the effective warranty of the battery.

At stage 4006, a determination is made as to whether the stored cumulative warranty value exceeds a predefined threshold. If the stored cumulative value exceeds the predefined threshold, method 4000 proceeds to stage 4008. At stage 4008, it is determined that the quality of the battery pack is due. If the stored accumulated value does not exceed the threshold, the method ends, indicating that the battery warranty has not expired.

FIG. 41 is a diagram illustrating an example battery pack and associated warranty information according to one embodiment. Analysis of warranty information may be performed when a battery pack is reported as defective. As shown in fig. 41, a battery pack 4104 exists in the electric storage unit 4102, similar to the battery pack of the electric storage unit 4802 of fig. 48A and 48B. In response to the battery pack 4104 having an operational problem, the battery pack 4104 is removed from the electrical storage unit 4102 for analysis.

In an embodiment, the battery pack 4104 may be connected to a computing device having a display 4106. In this manner, the battery pack operator, vendor, or manufacturer can view various warranty information and conditions to determine which party is economically responsible for servicing the battery pack 4104. In the example shown in fig. 41, the warranty threshold may be set at 500,000,000 and the cumulative warranty value for the battery pack is 500,000,049. Since the cumulative warranty value exceeds the warranty threshold, the battery warranty is determined to expire and the battery operator or owner should be financially responsible for the maintenance.

In an embodiment, warranty information of the battery pack 4104 may be viewed without physically removing the battery pack 4104 from the electrical storage unit 4102. For example, the stored warranty information may be sent to a device external to the battery pack 4104 via a network accessible for analysis.

Example testing of battery packs with operational problems or defects:

fig. 42 is a graph illustrating an example distribution of battery packs based on self-discharge rates and charge times according to an embodiment. Curve 4202 illustrates an example distribution of battery packs over a period of time based on the self-discharge rate 4206 of each battery pack. Axis 4204 indicates the number of battery packs having a particular self-discharge rate. Curve 4202 indicates a normal distribution where some battery packs have higher or lower self-discharge.

Curve 4208 illustrates a similar distribution of battery packs based on the charge time 4210 for each battery pack. In an embodiment, the timer may track the operating time of an inverter charger, such as inverter charger 2632 of fig. 26C, to determine the charging time of the battery pack over a period of time. Axis 4212 indicates the number of battery packs having similar charging times over a period of time.

As shown in fig. 42, the self-discharge rate and charge time of the battery pack are expected to be similar. In one embodiment, data for multiple battery packs may be collected over a period of time to determine

battery distributions

4202 and 4208. The average charge time of multiple battery packs may provide a reliable indication of the expected charge time of a healthy battery pack, e.g., a battery pack operating within acceptable tolerances. From these distributions, the maximum expected variance 4214 above the average charge time can be selected. For example, the maximum variance 4214 may be set to two standard deviations from the average charge time of the plurality of battery packs. In an embodiment, a charge time exceeding the maximum variance 4214 may indicate that the battery pack has an operational problem or defect. Those skilled in the art will recognize that the maximum variance 4214 may be any value above the expected charge time of the battery pack and may be static or dynamically updated as additional data is collected.

Fig. 43 is a graph of the relationship between temperature and charging time of a battery pack (such as battery pack 2600 of fig. 26A-26D) according to an embodiment. Curve 4302 shows a similar distribution of battery packs based on the charge time 4306 for each battery pack. Axis 4304 indicates the number of battery packs having similar charging times over a period of time. As shown in fig. 43, the curve 4302 represents the cell distribution based on a uniform cell temperature of 20 ℃ for each of the cell groups. In an embodiment, the battery temperature may be, for example, an average temperature of each battery cell or each battery module included in the battery pack.

Temperature has a significant effect on the performance of the battery pack. For example, higher temperatures may increase the self-discharge rate of the battery. In one non-limiting embodiment, the battery pack may self-discharge at 20 ℃ per month by 2% and increase to 10% per month at 30 ℃. Curve 4310 shows the distribution of battery packs based on the charge time 4306, where each cell has a temperature of 30 ℃. At 30 ℃, the charge time for each battery was maintained in the normal profile, but the average and expected charge times shifted.

Because the distributions shift at different temperatures, the maximum variance 4308 can be updated to compensate for temperature fluctuations. In an embodiment, one or more temperature sensors may monitor the average cell or battery module temperature of the battery pack. The temperature sensor may be internal or external to the battery pack. The maximum variance 4308 may then be dynamically adjusted in response to temperature changes. For example, if the average cell module temperature of the battery pack is determined to be 30 ℃, the maximum expected variance may be adjusted to a maximum variance 4312. This may prevent replacement of a healthy battery pack, for example, when the charge time of the battery pack decreases between the maximum variance 4308 and the maximum variance 4312 at a temperature of 30 ℃. In other embodiments, the ambient temperature may be monitored instead of or in combination with the battery module temperature, and the maximum variance 4308 may be dynamically adjusted in response to ambient temperature changes.

Fig. 44 is a diagram illustrating an example system for detecting a battery pack having an operational problem or defect according to an embodiment. In an embodiment, the system 4400 includes a battery pack 4402 and an analyzer 4408. It will be apparent to those skilled in the art that the detection techniques disclosed below may be implemented and used in the systems and methods described above. The battery pack 4402 may include an inverter charger 4404, such as the inverter charger 2632 and the timer 4406 of fig. 26C. The battery pack 4402 may be coupled to a power grid 4410. This causes the inverter charger 4404 to turn on and off as appropriate to charge the cells of the battery pack 4402.

In an embodiment, timer 4406 records the amount of time that inverter charger 4404 is operating. The timer 4406 is embedded within the battery pack as part of a battery pack controller, such as the battery pack controller 2800 of fig. 28. Alternatively, the timer 4406 may be separate from the battery pack controller. In an embodiment, timer 4406 may reset after a certain period of time or at certain time intervals. For example, the timer 4406 may be reset on the first day of each month in order to record the amount of time the inverter charger 4404 operates during that month. Alternatively, the timer 4406 may maintain an accumulated operating time or a specified charger run time, such as the time of operation over the last 30 days.

In an embodiment, the timer 4406 may periodically send the recorded operation time to the analyzer 4408. In an embodiment, the analyzer 4408 may be part of the battery pack 4402. For example, the analyzer 4408 may be integrated into a battery controller of the battery pack 2808, such as the battery controller 2800 of fig. 28. In other embodiments, the analyzer 4408 may be external to the battery pack 4402 and may be implemented on any computing system. In an embodiment where the battery pack 4408 is part of a BESS, such as BESS4802 of fig. 48A and 48B, the analyzer 4408 may be part of a string controller, an array controller, or a system controller as described with respect to fig. 48A.

In one embodiment, the analyzer 4408 may select a time period and compare the recording operation time for the selected time period to a threshold time. The threshold time may indicate a maximum determined variance from the expected operating time of the inverter charger 4406. The expected operating time may represent an expected charging time of the battery pack for a selected period of time, taking into account factors such as (but not limited to): battery usage and self-discharge rate. Analyzer 4408 may set the expected operating time and threshold time based on statistical analysis of data collected from multiple battery packs and may adjust as additional data is collected. If the battery pack 4402 is part of a battery pack array, the expected and threshold operating times can be determined based on an analysis of all or a subset of the battery packs in the array. Further, in an embodiment, the threshold time may be dynamically determined based on an average cell or battery module temperature of the battery pack or an ambient temperature surrounding the battery pack, as described above with respect to fig. 43. In an embodiment, one or more temperature sensors may monitor battery pack temperature or ambient temperature and provide measurements to analyzer 4408. The analyzer 4408 may then use the received temperature measurements to adjust the threshold time.

In an embodiment, if the recorded operating time exceeds a threshold time, the analyzer 4408 may determine that the battery pack has an operating problem or defect and may require maintenance and/or replacement. In this case, the analyzer 4408 may issue an alarm to an appropriate party, such as an operator in charge of monitoring the battery pack. In one embodiment, the alert may be issued as an email or other electronic communication. In other embodiments, the alarm that is issued may be audible or visual, such as a flashing red light on the battery pack, such as the warning described above with respect to the status buttons 2608 of fig. 26A and 26B.

In an embodiment, analyzer 4408 may also abort operation of the battery pack in response to determining that the battery pack has an operational problem or defect. This can serve as a mechanism for eliminating any adverse effect occurring when the battery pack having operational problems or defects is operated.

Fig. 45 is a diagram showing the collection of data from a battery array for analysis according to an embodiment. As explained, an energy system, such as the electrical storage system 4802 of fig. 48A (lower panel), includes a plurality of battery packs 4502. Each battery pack 4502 may include a timer to record the amount of time the battery pack is charged. The recorded time may be stored in each battery pack, as shown in fig. 4504. In an embodiment, each timer may be integrated into a battery pack controller of each battery pack, such as battery pack controller 2800 of fig. 28, including a processor and memory to store the recorded time.

In an embodiment, the recording time of each battery pack may be aggregated by one or more string controllers (such as string controller 4804 of fig. 48A below), as shown at 4506. And/or by an array controller (such as the array controller 4808 of fig. 48A below) and/or by a system controller (such as the system controller 4812 of fig. 48A), as shown at 4508. As shown in fig. 45, each string controller may manage a subset of the plurality of battery packs.

In an embodiment, the aggregated recording times may be sent by one or more string controllers or array or system controllers to one or more parsers 4510, such as parser 4408 of fig. 28. The analyzer 4510 may collect data on a plurality of battery packs in order to detect and identify battery packs having operational problems or defects, as described with respect to fig. 44. In one embodiment, the analyzer 4510 may be part of each string controller and/or array or system controller. In this way, the analysis may be localized on groups of battery packs, or performed for the entire system. In one embodiment, analyzer 4510 may be a flow chart illustrating an example method for detecting battery packs with operational problems or defects according to one embodiment at multiple battery packs, string controller, and array diagram 46. Each stage of the example method may represent computer readable instructions stored on a computer readable storage device, the computer readable instructions being executable by a processor to cause the processor to perform one or more operations.

Method 4600 begins with stage 4602, recording the amount of time the inverter charger is operating. The inverter charger may be part of a battery pack, such as inverter charger 2632 of fig. 26C, and is configured to charge cells of the battery pack.

In stage 4604, the recorded operation time for a particular time period is compared to a threshold time. The threshold time may indicate a variance of the determination from the expected operating time of the inverter charger. The expected operating time may represent an expected charging time of the battery pack for a selected period of time, taking into account factors such as (but not limited to): battery usage and self-discharge rate.

At stage 4606, a determination is made as to whether the recorded operation time exceeds a threshold time. This may indicate that the battery pack is charged longer than expected and may require maintenance and/or replacement. At stage 4608, if the recorded operating time exceeds a threshold time, an alert may be provided to an appropriate party, such as a computer or human operator (e.g., an energy management system) responsible for monitoring the battery pack. In one embodiment, the alert may be issued as an email or other electronic communication. In other embodiments, the alarm may be audible or visual, such as a red light on the battery pack. Returning to stage 4606, if the recorded operation time does not exceed the threshold time, the method ends.

Fig. 47 illustrates an example battery energy storage system ("BESS") 4700. Specifically, fig. 47 illustrates a cross-sectional view of BESS 4700. BESS 4700 can operate as a standalone system (e.g., commercial embodiment 4720) or it can be combined with a BESS unit to form part of a larger system (e.g., utility 4730). In the embodiment illustrated in fig. 47, BESS 4700 is housed in a container (similar to a freight container) and may be mobile (e.g., transported by truck). Other housings known to those skilled in the art are also within the scope of the invention.

As shown in fig. 47, BESS 4700 includes a plurality of battery packs, such as battery pack 4710. As shown in fig. 47, the battery packs can be stacked on a rack in BESS 4700. This arrangement allows an operator to easily access each of the battery packs for replacement, maintenance, testing, etc. Multiple battery packs may be connected in series, which may be referred to as a string of battery packs or battery string.

In one embodiment (explained in more detail below), each battery pack includes: battery cells (which may be arranged in a battery module); a battery pack controller that monitors the battery cells; an inverter charger (e.g., a direct current power supply) that adds energy to each of the battery cells; and, a distributed daisy-chained network of battery module controllers that can take certain measurements of the cells and remove energy from the cells. The battery pack controller may control the network of battery module controllers and the inverter charger to control the state of charge or voltage of the battery pack. In this embodiment. The battery pack included in BESS 4700 is considered a "smart" battery pack that can receive a target voltage or state of charge value and self-inverter to a target level.

Fig. 47 illustrates that BESS 4700 is highly scalable, from small kilowatt-hour-scale systems to multi-megawatt-hour-scale systems. For example, commercial embodiment 4720 of fig. 47 includes a single BESS unit that can provide 400kWh of energy (but is not limited thereto). Commercial embodiment 4720 includes a Power Control System (PCS)4725 that is mounted to the housing on the back of the BESS unit 4725. PCS 4725 may be connected to the grid. PCS 4725 includes one or more bi-directional power converters that can charge and discharge a plurality of battery packs using commands issued over a network (e.g., internet, ethernet, etc.) by an operator of an energy monitoring station, for example, via a computer. PCS 4725 can control the real and reactive power of a bi-directional power converter. Also, in certain embodiments, the PCS 4725 can operate as a backup power source when the power grid is unavailable and/or the BESS 4720 is disconnected from the power grid.

On the other hand, the utility embodiment 4730 of FIG. 47 includes six BESS units (labeled 4731) 4736), each of which is capable of providing 400kWh of energy (but is not limited thereto). Thus, utility embodiments 4730 together can provide 2.4MWh of energy. In a utility embodiment, each of the BESS units are connected together to a central PCS 4737 that includes one or more bi-directional power converters that can charge and discharge a plurality of battery packs using commands issued over a network (e.g., the internet, ethernet, etc.) by, for example, an operator of an energy monitoring station via a computer. PCS 4737 can control the real and reactive power of a bi-directional power converter. PCS 4737 may be coupled to a power grid. Also, in certain embodiments, the PCS 4737 can operate as a backup power source when the grid is unavailable and/or the BESS is disconnected from the grid.

FIG. 48A is a block diagram illustrating an example BESS4802 according to an embodiment. BESS4802 may be coupled to an Energy Management System (EMS)4826 via a communication network 4822. The communication network 4822 may be any type of communication network including, but not limited to, the internet, a cellular telephone network, etc. Other devices coupled to communication network 4822, such as computer 4828, may also communicate with BESS 4802. For example, computer 4828 may be located at the manufacturer of BESS4802 to maintain (monitor, run diagnostic tests, etc.) BESS 4802. In other embodiments, computer 4828 may represent a mobile device of a field technician performing maintenance on BESS 4802. The on-site monitoring device 4824 may also be coupled to the EMS4826 via a communication network 4822. The on-site monitoring device 4824 can be coupled to an alternative energy source (e.g., a solar power plant, a wind power plant, etc.) to measure the energy generated by the alternative energy source. Likewise, monitoring device 4818 may be coupled to BESS4802 and measure the energy generated by BESS 4802. Although two monitoring devices are shown in fig. 48A, one skilled in the art will recognize that additional monitoring devices monitoring energy generated by an energy source (conventional and/or alternative energy sources) may be connected to communication network 4822 in a similar manner. A human operator and/or computerized system at the EMS4826 can analyze and monitor the output of monitoring devices connected to the communication network 4822 and remotely control the operation of the BESS 4802. For example, EMS4826 may direct BESS4802 to charge (draw energy from the grid via PCS 4820) or discharge (provide energy to the grid via PCS 4820) as needed (e.g., to meet demand, stabilize line frequency, etc.).

BESS4802 includes a hierarchy of control levels used to control BESS 4802. The control hierarchy of BESS4802 is, in order from the top, a system controller, an array controller, a string controller, a battery pack controller, and a battery module controller. For example, the system controller 4812 may be coupled to one or more array controllers (e.g., array controller 4808), each of the array controllers may be coupled to one or more string controllers (e.g., string controller 4804), each of the string controllers may be coupled to one or more battery pack controllers, each of the battery pack controllers may be coupled to one or more battery module controllers. The battery pack controller and battery module controller are mounted with the battery packs 4806(a) -4806(n), as discussed in detail above with respect to fig. 26A-26B, 27A-27B, 28 and 29.

As shown in fig. 48A, the system controller 4812 is coupled to the monitoring device 4818 via communication link 4816(a) and to the communication network 4822 via communication link 4816(b), and to the PCS4820 via communication link 4816 (c). In fig. 48A, communication links 4816(a) - (c) are MOD buses, but any wired and wireless communication links may be used. In one embodiment, system controller 4812 is also connected to communication network 4822 through TCP/IP connector 4817.

System controller 4812 may monitor the operation of BESS4802 and report the operation of BESS4802 to EMS4826 or any other device connected to communication network 4822 and configured to communicate with BESS 4802. The system controller 4812 may also receive and process instructions from the EMS4826 and forward the instructions to the appropriate array controller (e.g., array controller 4806) for execution. The system controller 4812 may also communicate with the PCS4820, which PCS4820 may be coupled to the grid to control the charging and discharging of BESS 4802.

Although in fig. 48A, system controller 4812 is shown disposed in BESS4802, in other embodiments, system controller 4812 may be disposed outside of BESS4802 and communicatively coupled to BESS 4802. Considering fig. 47 again, commercial embodiment 4720 may be a separate unit used by a business, apartment, hotel, etc. A system controller may be disposed within the BESS of commercial embodiment 4720, for example, to communicate with an EMS or computer at a business, apartment, hotel, etc., via a communications network.

In other embodiments, such as the utility embodiment 4730, only one of the

BESS units

4731 and 4736 may include a system controller. For example, in fig. 47, the BESS unit 4731 may include a system controller and the

BESS unit

4732 and 4736 may not include a system controller. In this case, the BESS 4731 is considered a master and is used to control the BESS units 4732 + 4736, and the BESS units 4732 + 4736 are considered slaves. Also, in this case, the highest level of control included within each of the BESS units 4732-4736 is an array controller that is coupled to and in communication with a system controller within the BESS unit 4731.

Considering again fig. 48A, the system controller 4812 is coupled to the array controller 4808 via communication link 4814. The array controller 4808 is coupled to one or more string controllers, such as string controller 4804, via communication link 4810. Although fig. 48A depicts three string controllers (SC (1) - (3)), more or fewer string controllers may be coupled to the array controller 4808. In fig. 48A, the communication link 4810 is a CAN bus and the communication link 4814 is a TCP/IP link, but other wired or wireless communication links may also be used.

Each string controller in BESS4802 is coupled to one or more battery packs. For example, the string controller 4804 is coupled to battery packs 4806(a) - (n) that are connected in series to form a battery string. Any number of battery packs may be connected together to form a battery pack string. The battery strings can be connected in parallel in the BESS 4802. Two or more battery strings connected in parallel may be referred to as an array battery or an array of battery packs. In one embodiment, BESS4802 includes a battery array having six parallel strings of batteries, where each string of batteries has 22 batteries in series.

As the name implies, the string controller may monitor and control the battery packs in the battery pack string. The functions performed by the string controller may include (but are not limited to) the following: sending out a control command of a battery series contactor; measuring a battery string voltage; measuring the battery streaming; calculating the ampere hour count of the battery string; relaying queries between the system controller (e.g., at a charging station) and the battery pack controller; processing the inquiry response message; collecting battery string data; performing an assignment of the software device ID to the battery pack; detecting a ground fault current in the battery string; and, detecting alarm and warning conditions and taking appropriate corrective action. Example embodiments of string controllers are described below with respect to fig. 30, 31A, and 31B.

Also, the array controller may monitor and control the battery array. The functions performed by the array controller may include (but are not limited to) the following: sending a status query to the battery string; receiving and processing an inquiry response from the battery string; executing the control of the series contactor of the battery pack; broadcasting battery array data to a system controller; processing the alarm message to determine the required action, responding to a manual command or query from the command line interface (e.g., at the EMS), allowing a technician to set or change configuration settings using the command line interface, running a test script consisting of the same command and query understood by the command line interpreter; and broadcasting the data generated by the test script to a data server for collection.

Fig. 48B illustrates a cross-sectional view of an example BESS. Fig. 48B shows three battery strings ("string 1", "string 2", and "string 3"), each of which includes a string controller ("SC 1", "SC 2", and "SC 3", respectively) and 22 batteries connected in series. Strings 1-3 may be connected in parallel and controlled by array controller 4808.

In string 1, each of the 22 battery packs ("BP 1" to "BP 22") is labeled, showing the order in which the battery packs are connected in series. That is, BP1 is connected to the positive terminal of the string controller (SC1) and BP 2, BP 2 is connected to BP1 and BP3, BP3 is connected to BP 2 and BP4, and so on. As shown, BP 22 is connected to the negative terminal of SC 1. In the fig. 48B embodiment, SC1 may have access to the middle of string 1 (i.e., BP11 and BP 12). In an embodiment, the midpoint is grounded and comprises a ground fault detection means.

BESS4802 includes one or more lighting units 4830 and one or more fans 4832, which may be disposed in the ceiling of BESS4802 at regular intervals. Lighting unit 4830 can provide lighting to the interior of BESS 4802. Fans 4832 are oriented so that they blow air from the ceiling toward the floor of BESS4802 (i.e., they blow into the interior of BESS 4802). BESS4802 may also include a split air conditioning unit including an air handling device 4834 housed within the housing of BESS4802 and a condenser 4836 housed outside the housing of BESS 4802. The air conditioning unit and fan 4832 can be controlled (e.g., by the array controller 4808) to form an air flow system and to regulate the temperature of the battery pack housed within the BESS 4802.

Example BESS housing

Fig. 49A, 49B, and 49C are diagrams illustrating an enclosure (e.g., a custom shipping container) of an example BESS 4900. In fig. 49A-49C, the back and front of the housing of BESS 4900 are labeled. As shown in fig. 49A-49C, one or more PCS 4910 may be mounted on the back of BESS 4900, which couples the BESS 4900 to the grid. The front of BESS 4900 may include one or more doors (not shown) that may provide access to the inside of the enclosure. An operator may enter the BESS 4900 through a door and access internal components (e.g., battery packs, computers, etc.) of the BESS 4900. Fig. 49A depicts BESS 4900 with its housing top in place.

Fig. 49B depicts BESS 4900 with its housing top removed. As can be seen, the BESS 4900 includes one or more ceilings 4920, one or more lighting units 4930, and one or more fans 4940. The lighting units 4930 and the fans 4940 may be disposed in the ceiling 4920 at regular intervals. The lighting unit 4930 is capable of providing lighting to the interior of BESS 4900. The fans 4940 are oriented such that they blow air from the ceiling 4920 toward the floor of the BESS 4900 (i.e., they blow into the interior of the BESS 4900). An opening 4950 above the battery rack housed in the BESS 4900 allows warm air to be blown up into the space between the top of the enclosure and the ceiling 4920, forming a hot air zone above the ceiling 4920. Fig. 49C depicts BESS 4900 with the ceiling 4920 removed. It can be seen that an opening 4950 is provided above the battery pack rack housed in BESS 4900.

Fig. 50A, 50B, and 50C are diagrams illustrating an example BESS5000 without an outer shell (i.e., the internal structure of the BESS 5000). Fig. 50A and 50B illustrate the rack of the battery pack housed in the BESS5000, viewed from different angles. Fig. 50C illustrates a front view of BESS 5000. This is a view that may be seen by an operator opening a door in front of the BESS5000 and entering the BESS5000 to perform maintenance or testing. Fig. 50C illustrates a split air conditioning unit 5010 at the back of BESS 5000. The air conditioning unit 5010 is controlled (e.g., by an array controller) to adjust the temperature of the BESS 5000. The air conditioning unit 5010 provides cool air to the inside of the BESS5000 and forms a cool air area in the walkway of the BESS 5000.

Fig. 51 illustrates another front view of an example BESS 5100 and depicts air flow in the BESS 5100. As explained with respect to fig. 49A-49C and 50A-50C, a fan in the ceiling of the BESS 5100 blows hot air from a hot air area 5100 above the ceiling toward the floor of the BESS 5100. The a/C unit at the back of the BESS 5100 draws hot air from the BESS 5100 and provides cool air into the interior of the BESS 5100, forming a cool air zone 5120. The cold air conditions the temperature of the battery pack contained in the BESS 5100 and rises to the hot air zone 5110 as it cools the battery pack.

Fig. 52A and 52B are diagrams illustrating an example BESS5200 connection to a bidirectional power converter 5202. In one embodiment, the BESS5200 includes two

external HVAC units

5204a and 5204 b. In one embodiment, the bidirectional power converter 5202 may charge and discharge a plurality of battery packs disposed within the BESS5200 by sending a request over a network (e.g., the internet, ethernet, etc.) via a computer by an operator at an energy monitoring station.

Fig. 52B is a more detailed view of the BESS5200, as shown in fig. 52B, in one embodiment the BESS5200 may have a plurality of doors 5206 that can be opened to gain access to stacked batteries 5208, which can be installed and removed in the BESS5200 by a lift truck (not shown). This allows each stacked cell 5208 to be installed as a separate unit outside the BESS5200 and for shipping and installation.

Fig. 53A and 53B are diagrams further illustrating BESS5200, according to an embodiment. Fig. 53A shows a back view of the BESS5200 with the door 5206 closed, and fig. 53B shows a back view of the BESS5200 with the door 5206 open.

Fig. 54A, 54B, and 54C are diagrams showing the BESS5200 with its door in an open state and top removed. BESS5200 is shown equipped with a plurality of stacked cells 5208. In one embodiment, the BESS5200 also includes a switching device 5210, which is disposed at an end of the BESS 5200.

Fig. 54B illustrates a more detailed switching device 5210, in accordance with an embodiment. Fig. 54C shows another view of an embodiment including a switching device 5210 disposed at one end of the BESS 5200.

Fig. 55A, 55B,55C, and 55D are diagrams illustrating a modular, stackable BESS system according to various examples of an embodiment. Fig. 55A shows a BESS 5500 with fifteen stacked batteries 5208, an air conditioning switchgear unit 5502, and a dc switchgear unit 5504. In one embodiment, each stacked cell 5208 may be mounted as a separate unit either externally or internally to the BESS 5500.

Fig. 55B shows a BESS 5510 having nine stacked batteries 5208, an ac switchgear unit 5502 and a dc switchgear unit 5504. Fig. 55C shows a BESS 5520 having five stacked batteries 5208, an ac switching unit 5502, and a dc switching unit 5504. Fig. 55D shows a BESS 5530 having seven stacked batteries 5208, an ac switchgear unit 5502 and a dc switchgear unit 5504.

Fig. 56A, 56B,56C,56D and 56E show a modular, stackable stacked battery 5208 in accordance with an embodiment. The stacked cell 5208 has one stacked cell controller 5602 (which may also be referred to herein as a cell string controller) and seventeen stacked cells 5604 organic glass baffles 5606 protect the surfaces of the stacked cell controller 5602 and the stacked cells 5604. The stacked battery 5208 has a base 5608 so that it can be lifted or moved by a lift truck (not shown) or similar device. Fig. 56B shows another view of the stacked cell 5208 with the organic glass barrier 5606 removed, according to an embodiment.

Fig. 56C is an exploded view of stacked cells 5602 according to an embodiment. As shown in fig. 56C, the stacked battery 5620 can have one stacked battery controller 5602, nine stacked batteries 5604, and one stacked battery base 5608 fig. 56D is another exploded view of the stacked battery 5608 further illustrating the stacked battery base 5608, according to an embodiment. Fig. 56E is a view of a stacked cell 5208 further illustrating the stacked cell housing 5608, in accordance with an embodiment.

57A,57B,57C,57D,57E, and 57F are diagrams illustrating a modular, stacked battery 5604 (which may also be referred to herein as a battery cell) according to one embodiment. The battery pack 5604 may have a similar function and a similar structure to the battery pack 104 of fig. 1B and the battery pack 2600 of fig. 26A through 26D, described in detail above.

Fig. 57A illustrates a battery pack 5604 with the plexiglass baffle 5606 installed fig. 57B illustrates a battery pack 5604 with the plexiglass baffle 5606 removed fig. 57B shows that the battery pack 5604 has one battery pack control unit 5702. The functions and structures of the battery pack control unit 5702 or the battery pack controller have been described above.

Fig. 57C is another view illustrating the battery pack 5604 with the top portion removed. Fig. 57D is a view illustrating a battery pack 5604 with a casing removed to be able to better see the battery cells 5704 used in the battery pack 5604. Fig. 57E is a view illustrating the battery pack 5604 from which the battery pack control unit 5702 is removed. As shown in fig. 57E, a battery pack 5604 includes two

battery assemblies

5710a and 5710 b.

Fig. 58A,58B, and 58C are diagrams of a stacked battery 5604 further showing modularization according to the embodiment. Fig. 58A shows a battery 5604 with a plexiglass baffle 5606 installed.

Fig. 58B is an exploded view of the plastic glass baffle 5606, battery control unit 5702, and battery assemblies 5710a and 5710n showing battery pack 5604. These components of the battery stack 5604 may be packaged within a stack housing 5802. Fig. 58C is another exploded view of the plastic glass baffle 5606, battery control unit 5702, and

battery assemblies

5710a and 5710b showing battery pack 5604.

Fig. 59A,59B, and 59C are diagrams of a battery assembly 5710 showing a modular, stacked battery pack 5604, according to an embodiment. As shown in fig. 59A, battery assembly 5710 includes battery cells 5704, battery module control unit 5902, and bus 5904 each battery module control unit 5902 may monitor and control two groups of battery cells, where each group of battery cells is connected in parallel with one or more battery cells 5704. Battery module control unit 5902: (

Referred to as a battery module controller) has been described above.

Fig. 59B is an exploded view of a battery assembly 5710. In one embodiment, each battery assembly 5710 has four battery module control units 5902 fig. 59C is a more detailed view of one battery module control unit 5902. The battery module control unit 5902 may have similar functions and similar structures as the battery module controller 2638 described above with respect to fig. 26C, or may have similar functions and similar structures as the battery module controller 2900 described above with respect to fig. 29.

Fig. 60A and 60B are diagrams illustrating an exemplary battery controller 5602 according to an embodiment. In fig. 60A, a battery controller 5602 in which an organic glass baffle 5606 is mounted is illustrated. Fig. 60B is an exploded view of a battery pack controller 5602. The function and structure of the battery controller 5602 have been described above, for example, with respect to the string controller 3000 of fig. 30.

Fig. 61A,61B,61C, and 61D are diagrams illustrating an exemplary battery controller 5702. Fig. 61A shows a diagram of a first perspective of the battery controller 5702. Fig. 61B shows a diagram of a second perspective of the battery controller 5702. Figure 61C shows a diagram of a third perspective of the battery pack controller 5702 separate from the back cover. Figure 61D shows a diagram of a fourth perspective of the battery pack controller 5702 separate from the back cover. The function and structure of the battery controller 5702 has been described above, for example, with respect to the battery controller 414 of fig. 4 and 5 or the battery controller 2710 of fig. 27A-27B or the battery controller 2800 of fig. 28.

Given the description herein, various features of the invention can be implemented using processing hardware, firmware, software, and/or combinations thereof, such as an Application Specific Integrated Circuit (ASIC), as will be appreciated by those skilled in the relevant art(s). Implementing these features using hardware, firmware, and/or software will be apparent to one skilled in the relevant art. Also, while various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. It will be apparent to those skilled in the relevant art that various changes can be made without departing from the scope of the invention.

It should be appreciated that the detailed description section, and not the summary and abstract sections, is intended to be used to interpret the claims. The summary and abstract sections may set forth one or more, but not all exemplary embodiments of the present invention as contemplated by the inventor(s), and are therefore not intended to limit the invention and the claims in any way.

Embodiments of the invention have been described above with the aid of functional building blocks illustrating the implementation of the specified functions and relationships thereof. Boundaries of these functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternate boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed. Also, identifiers such as "(a)", "(b)", "(i)", "(ii)" and the like are sometimes used for different elements or steps. These identifiers are used for clarity and do not necessarily indicate an order of the elements or steps.

The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Accordingly, such adaptations and modifications are intended to be within the meaning and range of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.

The scope and breadth of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

Claims

1. A battery system, comprising:

stacking the battery bases;

a plurality of stacked battery packs are arranged on the top of the battery pack base; and

a stacked battery controller is in electrical communication with one of the plurality of stacked batteries and is configured to be in communicative connection with a plurality of stacked batteries, wherein each of the plurality of stacked batteries comprises:

a plurality of battery cells; and

a battery pack controller configured to control the plurality of battery cells to adjust electrical energy storage of the battery cells according to information received from the stacked battery pack controller;

it still includes:

a plurality of battery pack dischargers connected to the battery pack controller and configured to individually discharge each of the battery cells; and

a battery pack charger connected to the battery pack controller and configured to charge each of the battery cells in the plurality of stacked battery packs;

the battery controller of each stacked battery is configured to regulate the battery through a plurality of battery dischargers and chargers;

the battery controller of the stacked battery is further configured to:

directing a battery pack charger to charge a plurality of cells until a voltage of one of the cells exceeds a first charge threshold;

instructing the battery pack charger to charge the plurality of battery cells when the voltage of each battery cell is reduced until the voltage of each battery cell exceeds a second charging threshold;

the battery pack dischargers are guided to discharge the battery monomers until the voltage of each battery monomer is reduced to be between a first charging threshold value and a second charging threshold value; and

an ampere hour value and a watt hour value are determined for charging a plurality of cells.

2. A battery system according to claim 1, the battery controller of the stacked battery pack further configured to:

directing a plurality of battery pack dischargers to discharge a plurality of stacked battery cells until a voltage drop of one of the battery cells is below a first discharge threshold;

directing a plurality of battery pack dischargers to discharge the plurality of battery cells when the voltage decreases until the voltage of each battery cell is below a second discharge threshold; and

an ampere hour value and a watt hour value are determined for discharging the plurality of battery cells.

3. A battery system according to claim 1, wherein said battery pack regulation is based on a battery regulation flag set by a regulation trigger.

4. The battery system of claim 3, wherein the adjustment trigger triggers the adjustment of the cell balancing when the states of charge of at least two cells differ from at least two predetermined thresholds.

5. A battery system according to claim 1, further comprising a battery system controller configured to transmit charge-discharge signal commands to the cell stack controllers of all of the stacked battery packs through the stacked battery pack controllers.

6. The battery system of claim 5, wherein the charge-discharge signal instructions comprise an initial charge current, a reduced charge current, an initial discharge rate, and a reduced charge rate.

7. The battery system according to claim 5, wherein the charge-discharge signal command includes at least one of a charge start time, a charge stop time, a charge duration, a discharge start time, a discharge stop time, and a discharge duration.

8. An electrical energy storage system comprising:

a battery base;

a plurality of battery packs are connected together and arranged at the top of the battery pack base;

a battery pack controller in electrical communication with one of the plurality of battery packs and configured to be in communicative connection with the plurality of battery packs; and

a battery system controller configured to be communicatively coupled to the battery pack controllers, wherein each battery pack comprises:

a plurality of battery cells: and

a battery pack controller configured to control electrical energy storage of the battery cells by information received from the stacked battery pack controller;

it still includes:

a plurality of battery pack dischargers arranged to individually discharge each of the battery cells; and

a battery pack charger coupled to the battery pack controller and configured to charge the cells of each stacked battery pack;

wherein the battery system controller is further configured to direct the battery pack controller of each stacked battery pack to regulate the stacked battery pack through a plurality of battery pack dischargers and battery pack chargers;

wherein the regulating stacked battery, the battery controller is further configured to:

the battery pack charger is guided to charge the plurality of battery cells until the voltage of one battery cell reaches a first charging threshold value;

the battery pack charger is guided to charge the plurality of battery monomers when the voltage of the battery monomers is reduced until the voltage of each battery monomer exceeds a second charging threshold value;

the battery dischargers are guided to discharge the battery monomers until the voltage of each battery monomer is reduced to be between a first charging threshold value and a second charging threshold value; and

9. An electrical energy storage system according to claim 8, wherein the regulatory stack battery, the battery controller is further configured to:

the battery pack discharger is guided to discharge the plurality of battery monomers until the voltage of one battery monomer is lower than a first discharge threshold value;

the battery pack discharger is guided to discharge the plurality of battery monomers when the voltage of the battery monomers is reduced until the voltage of one battery monomer is lower than a second charging threshold value; and

an ampere hour value and a watt hour value are determined for discharging the plurality of cells.

10. An electrical energy storage system according to claim 8 wherein the conditioning of the stacked battery pack is based on a battery conditioning flag set by a conditioning trigger.

11. An electrical energy storage system according to claim 10 wherein the regulation trigger triggers the adjustment of the equalization of the cells when the state of charge of at least two cells differs from at least two predetermined thresholds.

12. An electrical energy storage system according to claim 8 wherein the battery system controller is configured to transmit charge-discharge signal commands to the battery pack controllers of all of the stacked battery packs via the stacked battery pack controllers.

13. An electrical energy storage system according to claim 12 wherein the charge-discharge signal commands include an initial charge current, a reduced charge current, an initial discharge rate and a reduced charge rate.

14. An electrical energy storage system according to claim 12, wherein said charge-discharge signal instructions include at least one charge start time, at least one charge stop time, a charge duration, a discharge start time, a discharge stop time, and a discharge duration.