CN118056188A - Large battery management system with gateway PCBA - Google Patents

Abstract

A battery system having large lithium ion battery packs provides power to accessory devices by discharging battery cells distributed among the plurality of battery packs. The intelligent lithium ion battery pack uses the analog signal to generate a limp home notification to one or more application devices. The battery pack may provide broadcast messages, including state of charge (SoC), fault conditions, etc., over the electronic communication lines, which may be read by one or more application devices to enter a limp home mode. In another example, the intelligent lithium ion battery pack uses analog signals to generate a "full charge" notification to one or more application devices. The terminal device powered by the battery system receives and reacts to the output fully charged signal by modifying the state of the circuitry on the terminal device.

Description

Large battery management system with gateway PCBA

Cross Reference to Related Applications

The present application claims the benefit of the priority of the co-pending continuation application of U.S. patent application Ser. No. 17/563,856 (attorney docket No. 009231.00224) filed on day 28 of 12 of 2021, which is a non-provisional application claiming the benefit of the priority of the co-pending U.S. provisional application Ser. No. 63/243,968 (attorney docket No. 009231.00226) filed on day 14 of 9 of 2021. And all of the above applications are incorporated by reference herein in their entirety.

In addition, the present application claims the benefit of the priority of the co-pending continuation application of U.S. patent application Ser. No. 17/563,916 (attorney docket No. 009231.00225) filed on day 28 of 12 of 2021, which is a non-provisional application claiming the benefit of the priority of the co-pending U.S. provisional application Ser. No. 63/243,968 (attorney docket No. 009231.00226) filed on day 14 of 9 of 2021. And all of the above applications are incorporated by reference herein in their entirety.

In addition, the present application claims priority from co-pending U.S. provisional application No. 63/243,968 (attorney docket No. 009231.00226) filed on day 2021, 9 and 14. And the above application is incorporated by reference in its entirety.

Technical Field

A battery system includes a plurality of battery packs. Each battery pack includes a battery management system in which one battery pack is flexibly configured as a master (e.g., primary) battery pack and the other battery packs are configured as slave (e.g., secondary) battery packs.

In one embodiment, the intelligent lithium ion battery pack uses analog signals to generate a limp home notification to one or more application devices. The battery pack may provide broadcast messages, including state of charge (SoC), fault conditions, etc., over the electronic communication lines, which may be read by one or more application devices to enter a limp home mode. This requires that the application device be able to read the message over the communication line; however, conventional application devices using lead acid batteries do not have this capability. The application device may monitor the battery voltage to determine when to enter a limp home mode. The battery pack voltage varies depending on load and temperature and is typically not an accurate estimate of the SoC. Further, the battery voltage is not typically indicative of a faulty battery in a multi-cell system.

In another embodiment, the intelligent battery pack has a Battery Management System (BMS) that uses complex algorithms, sometimes continuously calculating the battery pack state of charge (SoC). In such embodiments, the battery pack may output a signal (e.g., an analog signal) indicating that the battery pack is "fully charged. Similar to the output limp home mode signal described in the preceding paragraph, this signal may default to 0V, but be pulled up to 5V (or other voltage) or pack+ voltage when the SoC measurement reaches 100% or near 100%. As explained in the preceding paragraphs, some conventional application devices using lead-acid batteries do not have the ability to receive CAN communications, and therefore a gateway Printed Circuit Board Assembly (PCBA) that CAN read the SoC through an electronic communication protocol such as a Controller Area Network (CAN) CAN interface to the battery pack system. The reference voltage for the "fully charged" signal is PACK-. The terminal device uses the output "full charge" signal to drive the LED or an application controller connected to the terminal device.

The battery management systems and methods described herein may be implemented in industrial vehicle applications and commercial vehicle applications such as off-road utility vehicles, hybrid electric vehicles, battery electric vehicles, trucks/tractors, fork/pallet-lift trucks, lawn and garden/outdoor power equipment, large mining equipment, automated guided vehicles, aerial work platforms, and other such applications. Additionally, the systems and methods described herein may be implemented in other applications including, but not limited to, cordless power tools (e.g., drills, saws, grinders, nail drivers, welders, etc.), aerospace/defense applications, appliances, and other such applications. Moreover, the systems and methods described herein may be implemented in other applications including, but not limited to, grid energy storage, solar power generation and energy storage systems, sustainable power generation and energy storage systems, smart grid systems, telecommunication and data communication backup systems, unified Power Supply (UPS) systems, server applications, and other such applications.

For example, in some industrial and commercial vehicle applications, it may be desirable for a battery management system such as that disclosed herein to output a wide range of currents, e.g., higher currents when the engine of the vehicle is initially turned on, but lower currents during normal operation of the vehicle. In some embodiments, the battery management system and method may also include a limp home mode feature as disclosed herein to accommodate a faulty battery in a large battery pack, such as in an industrial vehicle application or a commercial vehicle application. Battery management systems including various battery pack configurations and one or more buses (e.g., CAN buses) may be integrated into industrial and commercial vehicle applications.

In another example, in some telecommunications and/or data communication backup systems and/or computer server applications, a battery management system such as disclosed herein may provide an alternative to lead-acid battery installations that have previously led to these applications due to their low cost, direct scalability, accessible recycling infrastructure, and accessible manufacturers. In some embodiments, the battery management systems and methods disclosed herein provide high energy density, high discharge rate capability, and low self-discharge characteristics that make integration into telecommunications and/or data communications backup systems, unified Power Supply (UPS) systems, and/or computer server applications desirable. For example, the above-described applications desire a longer run time range, which is made possible by a battery management system such as that disclosed herein, by implementing intelligent algorithms for charging, discharging, and balancing, such as intelligent converter balancing, starting direct balancing, starting interleaved balancing, etc., to extend the useful life of the batteries in the battery pack. Additionally, in some examples, the battery management systems and methods disclosed herein may be used with technologies such as fuel cells, supercapacitors, flywheels, and other electrochemical cells used in telecommunications/data communications backup applications.

In yet another example, in some grid energy storage systems, solar power generation energy storage systems, sustainable power generation energy storage systems, smart grid systems, and/or Unified Power Supply (UPS) systems, a battery management system such as that disclosed herein may optimize the grid and make sustainable energy sources such as wind and solar energy more economical. In one example, the system may be used to store solar energy received from a photovoltaic panel, and in some embodiments, the battery management system disclosed herein may be used to manage a bi-directional three-phase inverter system. The renewable energy storage system may include a plurality of batteries integrated into a battery pack in a rack-mounted chassis and a housing. Solar integrators may use the disclosed battery management systems and methods with large battery chemistries to meet the increasing demand for renewable energy storage. While lead-acid, supercapacitors, sodium-sulfur, vanadium redox, flywheel, compressed air, fuel cells, and pumped water have been used in solar storage applications, solar integrators may conveniently use lithium ions for large scale applications according to the disclosed battery management systems and methods. In addition, solar integrators may desire auxiliary services for the power market that use micropulses of energy to maintain the proper frequency of current on the power grid, such as frequency regulation, and advanced smart grid functionality such as micro grid operation, demand response, time shifting, and power scheduling. Lithium chemistry includes reduced weight, reduced volume/footprint, longer cycle life, ability to use a greater percentage capacity lithium battery without shortening rated cycle life, faster charge time, and lower effective capacity loss at high discharge rates, as compared to previous battery technologies. In some examples, inverter and gateway interoperability may be coupled to the disclosed battery management system to manage, distribute, and store energy within the smart grid. In some examples, the smart grid system may be housed in an expandable mobile transport container.

In addition to grid energy storage systems, the battery management systems and methods disclosed herein may be integrated with off-grid power products suitable for consumer, recreational, automotive, marine, and/or industrial applications. In the automotive field, auxiliary Power Units (APUs) may be used for transportation, construction and/or maintenance of important infrastructure. The battery APU provides a robust and reliable off-grid power supply for commercial vehicles. Other off-grid power applications include offshore power, remote location power, traffic regulations, safety monitoring, and emergency generators. Further, the battery APU may be used for short and long distance trucks, construction equipment, off-road transportation (e.g., felling trucks), and buses. For example, commercial trucks may rely on a battery APU to achieve overnight comfort (e.g., air conditioning/heat/accessory) loads. For several off-grid applications, reliability is a major concern because of the very high cost of failure and/or downtime.

Background

Battery technology has evolved from the early automated age when vehicle batteries were typically large heavy equipment using lead acid technology. Battery technology has evolved to provide more power in a smaller space. For example, lithium-ion (Li-ion) batteries are rapidly replacing conventional zinc-carbon and lead batteries because they are smaller and lighter than conventional batteries and can hold up to three times longer charge than conventional batteries that are both larger and heavier. Accordingly, lithium ion batteries are finding application for powering tools, appliances, and vehicles, including forklifts, cars, trucks, and the like. In addition, battery technology does not stagnate. For example, new solid state batteries use a glass electrolyte and lithium or sodium metal electrodes that provide approximately three times the energy density of a lithium ion battery. However, in general, if the sensitive chemical substances of the battery are damaged, the new technology battery may be damaged or deteriorated. For example, it is known that if overcharged or charged/overcharged/discharged in an improper manner, the lithium ion battery may malfunction/deteriorate.

Battery Management Systems (BMS) are sometimes included in new technology batteries, such as nickel metal hydride or lithium ion, to provide battery protection, to provide improved efficiency, and to provide a better user experience than previous battery technologies. Battery management systems may sometimes be implemented to facilitate one or more objectives. For example, the BMS may be used to protect users of battery-powered applications. As other examples, BMS may be used to protect the battery pack itself from damage and abuse, as batteries are often an expensive investment. In addition, since the battery may be an expensive investment, the BMS may be used to maximize the performance of the battery system. Still further, the BMS may serve to maximize the life of the constituent battery cells.

Disclosure of Invention

A battery system may include multiple battery packs that may have identical or similar electrical and electronic components and/or chemicals. Each battery pack may support battery cells (typically lithium ions). The battery pack does not need to require a specific configuration before the battery pack is installed in the battery system. Instead, after a battery pack is inserted into the system and activity on the communication channel is initiated without user intervention, the battery pack may assume the role of a master (e.g., primary) battery pack or a slave (e.g., secondary) battery pack.

In one aspect, a battery management system is disclosed that enables a smart lithium ion battery pack to notify one or more application devices that lack an electronic communication device, requiring the application devices to enter a limp home mode when certain conditions are met. These conditions include, but are not limited to: a state of charge (SoC) below a safety threshold, one or more battery packs in a multi-battery system failing, and/or any other condition requiring an application device to operate in a low power mode. Application devices that use conventional lead acid batteries and/or lead acid batteries without electronic communication capabilities are the primary focus of the features disclosed herein. In particular, any intelligent battery pack that internally calculates the SoC is the primary focus of the features disclosed herein. By adding a limp home signal, these devices can be upgraded to a lithium ion battery and monitor for a limp home signal.

According to another aspect, the battery system does not need to utilize an external battery management system. Instead, each battery pack may include an internal battery management system that may manage the battery cells of the battery pack and may coordinate via messaging with other battery packs in the battery system via a communication channel.

According to another aspect, the master battery pack may collect battery status information from one or more slave battery packs via messaging over the communication channel. Based on the state information, the master battery pack may appropriately initiate the enabling/disabling of the charge or discharge of the battery cells located at the slave battery packs.

According to another aspect, a configuration list may be sent by a master battery pack to a slave battery pack over a communication channel (e.g., a serial communication channel such as a Controller Area Network (CAN) bus), where the configuration list may include entries for each of the master battery pack and the slave battery packs. The entry at the top position may be used as a master battery pack while the other battery packs may be used as slave battery packs. When a battery pack is added or removed, the configuration list may be revised to reflect the change.

According to another aspect, battery packs in a battery system may be charge balanced to mitigate and/or prevent inrush current that may occur to one or more of a plurality of battery packs in the battery system when there is a significant change in state of charge (SoC) between the battery packs. For example, when a new battery pack is installed in a battery system, such as when the SoC of the new battery pack is significantly different (e.g., discharged, fully charged) from the existing battery packs in the battery system, large SoC changes may occur. Since the lifetime of lithium ion batteries may be significantly shortened, inrush current may be particularly undesirable.

According to another aspect, different battery balancing techniques are supported in a battery system. Based on the SoC characteristics of the battery pack, one of a variety of balancing techniques may be selected. Balancing techniques may include, for example, "intelligent converter balancing," start direct balancing, "and/or" start staggered balancing.

According to another aspect, a battery system may support a "limp home mode" when a battery pack in the battery system experiences a catastrophic failure, such as when its battery cells are characterized by a very low voltage output. The internal battery management system may diagnose the fault and may mitigate the fault by configuring an unused battery pack in the battery system (if available) or by initiating a partial shutdown of the battery system so that the device can operate "limp home" at least partially under power.

According to another aspect, the battery system supports "smart discharge" in order to power a device (terminal device). A battery pack having a varying SoC may be connected to the terminal device to provide power to the device. However, battery packs having large SoC variations cannot be immediately connected together to supply power to terminal devices, and charge balancing may need to be performed. The battery pack is then selectively activated from among a plurality of battery packs in the battery system so that the battery pack can be properly discharged.

According to another aspect, the battery system supports "smart charging" in order to resume charging of its battery cells. A battery system having battery packs with varying socs may be connected to a charger to restore the SoC of each battery pack and reduce SoC variability between battery packs. If the battery pack has a large SoC variation, the battery pack cannot be immediately connected to the charger at the same time. Thus, measures to avoid this are supported by enabling charging of the selected battery pack at the appropriate time based on the dynamic SoC characteristics.

According to another aspect, a battery system supports stackable charging, wherein multiple chargers are connected in parallel to charge a battery pack. In general, if one battery pack enters charge protection, the total current is supplied to the remaining battery packs, which may cause overcurrent charge protection in the remaining battery packs, and the charge may eventually stop. Battery characteristics are provided that identify the number of connected battery packs. The master battery pack combines the data from the battery packs and communicates with the master charger from the charger system and adjusts the current accordingly.

Drawings

The foregoing summary, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings, which are included by way of example, and not by way of limitation with respect to the claimed invention.

Fig. 1 shows a terminal device powered by a plurality of battery packs according to an embodiment.

Fig. 2A illustrates a battery pack having an internal Battery Management System (BMS) according to an embodiment.

Fig. 2B illustrates a battery pack having an internal Battery Management System (BMS) according to an embodiment.

Fig. 3 shows a flowchart of the entire process of powering a terminal device through a plurality of battery packs according to an embodiment.

Fig. 4 illustrates updating of a configuration list of a plurality of battery packs according to an embodiment.

Fig. 5 shows a flowchart for configuring a plurality of battery packs according to an embodiment.

Fig. 6A illustrates a general message flow scenario for configuring multiple battery packs according to an embodiment.

Fig. 6B illustrates a message flow scenario on a Controller Area Network (CAN) bus for configuring multiple battery packs according to an embodiment.

Fig. 6C illustrates another message flow scenario on a Controller Area Network (CAN) bus for configuring multiple battery packs according to an embodiment.

Fig. 6D illustrates another message flow scenario on a Controller Area Network (CAN) bus for configuring multiple battery packs according to an embodiment.

Fig. 7A shows a flowchart for determining a balance type of a plurality of battery packs according to an embodiment.

Fig. 7B shows a flowchart for selecting one of three balancing types for a plurality of battery packs according to an embodiment.

Fig. 7C illustrates a flowchart for determining a balance type of a plurality of battery packs according to an embodiment.

Fig. 8 illustrates a message flow scenario for determining a balancing type of a plurality of battery packs according to an embodiment.

Fig. 9 shows a flowchart for converter balancing multiple battery packs according to an embodiment.

Fig. 10 illustrates a message flow scenario for converter balancing multiple battery packs according to an embodiment.

Fig. 11 shows a flow chart for directly balancing a plurality of battery packs according to an embodiment.

Fig. 12 illustrates a message flow scenario for directly balancing multiple battery packs according to an embodiment.

Fig. 13 shows a flow chart for stagger balancing of multiple battery packs according to an embodiment.

Fig. 14 and 15 illustrate message flow scenarios for cross balancing multiple battery packs according to embodiments.

Fig. 16 shows an example of charging a plurality of battery packs according to an embodiment.

Fig. 17 shows a flowchart for charging a plurality of battery packs according to an embodiment.

Fig. 18A illustrates a message flow scenario for charging multiple battery packs according to an embodiment.

Fig. 18B illustrates a message flow scenario for charging multiple battery packs according to an embodiment.

Fig. 18C illustrates a flowchart of a method for intelligently charging a plurality of battery packs according to an embodiment.

Fig. 19A shows an example in which a plurality of battery packs are discharged to supply power to a terminal device according to an embodiment.

Fig. 19B shows an example in which a plurality of battery packs are discharged to supply power to a terminal device according to an embodiment.

Fig. 20A shows a flowchart for discharging a plurality of battery packs according to an embodiment.

Fig. 20B shows a flowchart for discharging a plurality of battery packs according to an embodiment.

Fig. 21 illustrates a message flow scenario for discharging multiple battery packs according to an embodiment.

Fig. 22 is a flow chart for limp home mode operation according to an embodiment.

Fig. 23A illustrates a message flow scenario for limp home mode operation according to an embodiment.

Fig. 23B illustrates a message flow scenario for limp home mode operation, according to an embodiment.

Fig. 24 shows a battery pack having a connector with a limp home mode signal output to an external device according to an embodiment.

Fig. 25A, 25B, and 25C (collectively, "fig. 25") are flowcharts of a connector outputting a limp home mode signal to an external device in accordance with one or more embodiments. Figure 25A is an embodiment of logic that determines when to activate a signal residing in the gateway PCBA. Fig. 25B is an embodiment in which logic resides in the battery system and the gateway PCBA reads/receives this signal from the master battery in the battery system and sets the hardware pins accordingly. Fig. 25C is an embodiment in which the hardware signals reside in the battery pack system and the gateway PCBA is not used.

Fig. 26A illustrates a message flow scenario where a connector outputs a limp home mode signal to an external device according to an embodiment.

Fig. 26B shows a message flow scenario where the connector outputs a limp home mode signal to the charger according to an embodiment.

Fig. 27 shows an illustrative battery pack with signal connectors.

Fig. 28 shows an illustrative gateway PCBA showing a connector.

Fig. 29A and 29B (collectively, "fig. 29") are flowcharts for the connector to output a "full charge" notification signal. Figure 29A is an embodiment in which hardware signals reside in the gateway PCBA. Fig. 29B is an embodiment in which the hardware signals reside in the battery pack system and the gateway PCBA is not used.

Fig. 30 shows an example of a stackable charging configuration when a plurality of chargers are connected in parallel to charge a battery pack.

Detailed Description

According to one aspect of the embodiments, a battery system having a large battery (e.g., lithium ion battery) supplies power to accessory devices (terminal devices) by discharging battery cells distributed among a plurality of battery packs. The discharge of the battery cell is controlled in an efficient manner while maintaining the life expectancy of the lithium ion battery cell. Some advantages of using lithium ion batteries over traditional lead acid batteries include longer run times, zero maintenance, faster charging, reduced weight, longer life, and better knowledge of battery parameters such as state of charge (SoC), state of health (SoH), etc. However, when switching from lead-acid batteries to lithium ion batteries, a charger needs to be considered. The charger types may include a stand-alone charger for lead acid replacement or an intelligent charger for intelligent batteries. Some lithium ion charging problems include charging compatibility, failure of the charger to charge the battery, failure of the charger to stop charging, stackable chargers and charging out of limits and communication problems.

According to another aspect of the embodiments, the battery system may support different advanced technology batteries of different chemistries and/or structures, including but not limited to lithium ion batteries and solid state batteries.

Each battery pack internally supports a Battery Management System (BMS), and thus, external battery management is not required, as compared with the conventional method. Furthermore, each of the battery packs may have identical electrical and electronic components, supporting an architecture that is easily scaled to higher power/energy outputs as required by the terminal device. The battery packs may be added or removed separately, with one of the battery packs serving as a master battery pack and the remaining battery packs serving as slave battery packs. Further, the configuration of the battery pack may be automatically performed without user interaction. When the master battery pack is removed, one of the slave battery packs is automatically reconfigured to the master battery pack. The master (e.g., primary) battery pack and the slave (e.g., secondary) battery pack coordinate charging and discharging of the battery cells through a communication channel such as a controller area Controller (CAN) bus.

In addition, the battery system can be effectively charged to restore the charging of the battery cells while maintaining the life expectancy of the battery cells.

A chargeable middle-to large-sized battery pack having a battery management system provides power to small-sized portable devices and also expands to larger mobile and stationary uses. Furthermore, for rechargeable batteries, it is conceivable to extend smaller uses such as scooters to transportation applications for larger uses such as full-size automobiles. Industrial applications are also envisaged as battery-based designs are replacing small internal combustion engines for lawn mowers and garden equipment in commercial and consumer products. Achieving electrification has several advantages, including, but not limited to, elimination of pollution emissions, noise reduction, and maintenance requirements. In addition, independent backup power systems for residential and commercial use benefit from battery-based designs that eliminate problems associated with on-site hydrocarbon-based fuel storage.

Fig. 1 shows a terminal device 101 according to an embodiment, the terminal device 101 being powered by a plurality of battery packs 100 (battery systems). Each battery pack 102, 103, and 104 includes its own internal Battery Management System (BMS) 112, 113, and 114, respectively. The battery packs 102, 103, and 104 are electrically connected to a Direct Current (DC) power bus 151 (including positive and negative connections) such that the voltage presented to the terminal device 101 is substantially the same as the voltage provided by each battery pack 102, 103, and 104, and the current provided to the terminal device 101 is the sum of the individual currents provided by each battery pack. The battery pack 100 may be housed within the terminal apparatus 101, mounted to the terminal apparatus 101, or located externally with respect to the terminal apparatus 101.

The terminal device 101 may employ different types of devices including, but not limited to, power tools, lawnmowers, garden tools, appliances, and vehicles including forklifts, cars, trucks, and the like.

The battery management systems 112, 113, and 114 communicate with all battery packs and the terminal device 101 and/or charger 1601 via a communication channel 152 (as shown in fig. 16). For example, the communication channel 152 may include a serial communication channel (e.g., a Controller Area Network (CAN) bus) or a parallel communication bus. However, these embodiments may support other types of communication channels, such as ethernet, industrial ethernet, I ² C, microwire, or Bluetooth Low Energy (BLE). In some cases, the communication channel may support synchronous communication (e.g., CAN) or asynchronous communication (e.g., RS-232, RS-422, RS-485, etc.).

CAN and ethernet protocols support the lower two layers of the OSI model, while BLE protocols span the lower layers and the higher layers including the application layer. Thus, embodiments utilizing protocols such as CAN and ethernet must support the equivalent higher layers through software applications built on top of the two lower layers.

These embodiments may support different messaging protocols. For example, a protocol may support node-to-node communication by supporting a source address and a destination address. The destination address may specify a particular node address or may be a global address so that messages may be broadcast to more than one node. In some cases, a protocol (e.g., CAN protocol, modbus protocol, etc.) may support only a single source address (e.g., master address) so that all nodes may process messages broadcast over a communication channel.

The battery packs 102, 103, and 104 may each be connected to the communication channel 152 in parallel. However, these embodiments may support different arrangements, such as group-to-group communication on separate buses or daisy-chain connection through each battery group.

The battery packs 102, 103, and 104 may have similar or identical electrical and electronic components. After being inserted into the battery system, one of the battery packs 102, 103, or 104 may be configured as a master battery pack or a slave battery pack. Furthermore, if the battery pack is initially used as a slave battery pack, the slave battery pack may then be used as a new master battery pack if the current master battery pack is removed.

Fig. 2A illustrates a battery pack 200 having an internal Battery Management System (BMS) according to an embodiment. The battery management system may be implemented by a processor 201 (which may include one or more microprocessors, controllers, microcontrollers, computing devices, and/or the like) to execute computer-executable instructions stored at a memory device 202.

As will be discussed, the battery pack 200 may be configured as a master battery pack or a slave battery pack without any changes to the electrical or electronic components.

As will be discussed, the power circuitry of the battery pack 200 (including the battery cells 203) interacts with the power bus 151 through the power bus interface circuitry 206 when the battery pack 200 is discharging, charging, and/or balancing with respect to other battery packs.

The battery pack 200 also interacts with the communication channel 152 via the communication channel interface circuit 205. For example, the battery pack 200 may support messaging with other configurations of battery packs, terminal devices powered by the battery packs, or chargers that charge the battery cells 203. Exemplary message flows are shown in fig. 6A-6B, 8, 10, 12, 14-15, 18A-18B, 21, and 23A-23B, as will be discussed in further detail.

The battery pack 200 supports core battery monitoring and/or management functions via the core battery function circuitry 204. For example, the core battery functions may include cell status, cell balancing, short circuit protection, high temperature shut-off, over-current shut-off, and overcharge protection.

Referring to fig. 2A, the battery cell 203 may include a plurality of battery cells connected in series to obtain a desired voltage level. For example, for lithium ion technology, each cell may have a nominal voltage of about 3.6 volts. In the case of four cells connected in series, the total nominal voltage provided by the battery pack 200 is approximately 14.4 volts. When the battery cell 203 includes a plurality of battery cells, the core battery function circuit 204 may internally balance the charge between the different battery cells. In addition, the battery pack 200 may be charge balanced with respect to other battery packs in the battery system. The battery packs are typically configured in parallel such that the resultant current provided to the terminal device is the sum of the battery pack currents at the approximate voltage level of the individual battery packs.

The state information may include state of charge (SoC) information, state of health (SoH) information, temperature information, charge time information, discharge time information, and/or capacity information of the battery cells and/or the battery pack.

As will be appreciated by those skilled in the art, soC is understood to be the charge level of a battery relative to its capacity. The unit of SoC is typically a percentile (0% = null; 100% = full).

SoH generally does not correspond to a particular physical quality, as there is generally no consensus in the industry as to how to determine SoH. However, soH indicates internal resistance, battery storage capacity, battery output voltage, number of charge-discharge cycles, temperature of the battery cell during previous use, total energy charged or discharged, and/or lifetime of the battery cell to derive a value of SoH. Knowing the SoH of the battery cells of the battery pack 200 and the SoH threshold of a given terminal device (application) may provide a determination of whether the current battery conditions are suitable for the application and an estimate of the useful life of the battery pack for the application.

When performing the processes associated with battery management, battery pack 200 may receive or transmit at least SoC and/or SoH values from or to other battery packs, as will be discussed in further detail.

The power bus interface circuit 206 may include switching circuitry such as a semiconductor array 210 (e.g., a MOSFET array or other power semiconductor switching device such as an Insulated Gate Bipolar Transistor (IGBT) array, a thyristor array, etc.) and a semiconductor array 211, the semiconductor array 210 allowing current to flow from the battery pack 200 when the battery pack 200 is discharged and the semiconductor array 211 allowing current to flow to the battery pack 200 when the battery pack 200 is charged. The arrays 210, 211 are suitably enabled by the processor 201 in response to messaging from the master battery controller. (in the case where the battery is the main battery, the message is transmitted inside the battery 200, rather than via the communication channel 152.) a power MOSFET array (e.g., an N-channel MOSFET) may be used as a switch to control the power flow to and from the battery cells. The gates of the MOSFET array may be controlled by signals generated by the microcontroller and/or the battery management IC.

The power bus interface circuit 206 may be configured to prevent the battery pack 200 from charging or discharging through the power bus 206 based on the state of the battery cells 203 (e.g., soC, soH, and/or voltage). Typically, when a battery is inserted into the battery system, arrays 210 and 211 are disabled such that the battery is not charged or discharged until commanded and/or controlled by the master battery.

The battery pack 200 interacts with the power bus 151 via an electrical switch 208 (which may include one or more semiconductor devices). As shown in fig. 2, direct exposure to the power bus 151 bypasses the converter 207. However, if the battery cell is charged when the battery cell has a small SoC, the battery cell may cause current inrush, which often results in damage or degradation. Thus, when the battery management system detects such a condition, the electrical switch 208 may be configured such that charging of the battery pack 200 is controlled to minimize the inrush current from the power bus 151 via the converter 207.

The converter 207 may take different forms capable of controlling the transfer of power between the power bus and the battery of the battery pack, such as by providing an output voltage that is stepped down relative to an input voltage (e.g., a buck converter,Converters, buck-boost converters, single-ended primary inductor converters (SEPIC) converters, etc.) to protect the battery cells 203 from current inrush and enable the battery cells 203 for slow charging (e.g., corresponding to the converter balancing flowchart 713 shown in fig. 9). However, when the converter 207 is bypassed, the battery unit 203 may charge at a faster rate (e.g., corresponding to the direct balancing flow chart 714 shown in fig. 11).

The processor 201 may support the battery management processes discussed herein (e.g., processes 500, 700, 713, 714, 715, 1700, 2000, and 2200 as shown in fig. 5, 7A, 9, 11, 13, 17, 20, and 22, respectively). The processor 201 may control the overall operation of the battery pack 200 and its associated components. The processor 201 may access and execute computer readable instructions from the memory device 202, which memory device 202 may employ various computer readable media. For example, computer readable media can be any available media that can be accessed by processor 201 and includes both volatile and nonvolatile media, and removable and non-removable media. By way of example, and not limitation, computer readable media may comprise combinations of computer storage media and communication media.

Computer storage media may include volatile and nonvolatile, and removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, random Access Memory (RAM), read Only Memory (ROM), electrically Erasable Programmable Read Only Memory (EEPROM), flash memory or other memory technology, CD-ROM, digital Versatile Disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by a computing device.

Communication media may include computer readable instructions, data structures, program modules, or other data in a modulated data signal, such as a carrier wave or other transport mechanism, and includes any information delivery media. The modulated data signal may be a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media may include wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and so forth.

While the processor 201 and the communication channel interface circuit 205 may be powered by the battery unit 203, embodiments may have separate power supplies for the processor 201 and the interface circuit 205. Accordingly, the battery pack 200 may continue to interact with other battery packs over the communication channel regardless of the state of the battery cells 203.

Fig. 2B shows a variation of the battery pack 200 shown in fig. 2A. The battery unit 203 interacts with the power bus through a power bus connector 214, a switch 217, a converter 218, and a connector 219. The switch 217 may include two sets (arrays) of semiconductor devices (e.g., MOSFETs, insulated Gate Bipolar Transistors (IGBTs), thyristors, etc.) for allowing current to flow in either direction (into the battery for charging and out of the battery for discharging). Both arrays may be disabled to isolate the battery pack from the power bus. Typically, both arrays are disabled when the battery pack is inserted into the battery system. In addition, the enabled converter 218 may be used to reduce the input voltage level to control the charging of the battery cells to prevent current inrush that may occur under certain conditions to be discussed.

The controller 213 executes computer-executable instructions to perform the processes discussed herein. For example, the controller 213 obtains status information (e.g., soC values) from the battery cells 203 via the battery monitor 220, provides battery pack status information via the status display 215, and interacts with a communication channel (e.g., CAN bus) via the communication bus interface 216.

In addition, the heater control circuit 212 may be used to ensure that the temperature of the battery cells 203 does not drop below a minimum value so that the battery cells 203 may function properly as intended.

Fig. 3 shows a flowchart 300 of an overall process of powering a terminal device (e.g., terminal device 101 shown in fig. 1) through a plurality of battery packs (e.g., battery pack 100) according to an embodiment.

At block 301, the terminal device 101 is activated. For example, the user may turn off the battery compartment of the terminal device 101, turn a key, and/or toggle a switch to generate an interlock signal.

At block 302, when the battery compartment has more than two battery packs, the battery management system of the master battery pack determines whether to balance the battery packs. If so, at block 303, the charge differential of the battery packs may be reduced by discharging one or more battery packs to charge one or more other battery packs, as will be discussed in further detail.

After balancing (if needed), the terminal device is powered by discharging one or more battery packs at block 304. For example, based on the power requirements of the terminal device and the SoC value of the battery pack, the battery management system of the master battery pack may enable the appropriate battery pack.

If a catastrophic failure of one of the enabled battery packs is detected at block 305 while the terminal device is powered, a limp home mode operation may be initiated at block 306 to continue powering the terminal device, as will be discussed in further detail.

When the user has completed using the terminal device at block 307, a determination is made at block 308 as to whether charging is required. If so, a charger may be connected to the battery system to restore the battery cells, wherein charging may be initiated at block 309.

Although not explicitly shown, when the SoC values of the battery packs are sufficiently different, balancing of the battery packs may be performed prior to charging the battery packs at block 308.

For these embodiments, all of the plurality of battery packs may have the same electrical and electronic components. When the battery pack is mounted in a battery system, it is generally not necessary to configure the battery pack. Instead, after the battery pack is inserted into the system and the battery pack begins to active on the communication channel, the battery pack assumes the role of a master battery pack or a slave battery pack based on the process discussed herein. As will be discussed in further detail, the list of configurations may be transmitted over a communication channel, wherein the configuration includes an entry for each of the master battery pack and the slave battery packs.

The processes discussed herein are shown from the perspective of the main battery and are typically performed by the main battery in a battery system. Other battery packs mounted in the battery system are used as slave battery packs. However, the slave battery packs interact with the master battery pack through the communication channel. For example, the slave battery packs provide their battery cell status information and activate/deactivate the power switch to interact with the power bus (e.g., allow current (charge) to flow into or out of the battery pack) in response to messaging from the master battery pack. Thus, although not explicitly shown, there is a corresponding procedure performed by each of the slave battery packs.

Fig. 4 shows updating of configuration lists 401a, 401b, 401c, 401d of a plurality of battery packs when different battery packs are inserted into and removed from the battery system. Each battery pack is assigned an Identification (ID) according to a standardized procedure, such as an SAE J1939 address declaration procedure and/or the like. For example, configuration list 401a contains four entries: a battery pack 1 (which is configured as a master battery pack) and three slave battery packs (battery packs 2 to 4).

As will be discussed in more detail, the master battery pack gathers status information about other battery packs (slave battery packs) and thus instructs the slave battery packs to discharge or charge themselves in response to operating conditions.

For the embodiment shown in fig. 4, the first (top) member of the configuration list 401a, 401b, 401c, 401d is configured as the master battery pack. When a battery pack is added to the battery system, an entry is created for the battery pack at the bottom of the configuration list. Thus, the oldest member in the configuration list 401a, 401b, 401c, 401d is configured as the master battery pack.

Selecting the oldest (top) member of the configuration list 401c may be advantageous to conventional approaches. For example, with respect to determining the main battery pack based on the ID value, the number of changes of the main battery pack can be reduced. With the latter method, a second change will occur from the configuration list 401d, wherein the battery pack 5 will become the master battery pack.

In the installation scenario shown in fig. 4, battery pack 1 (which serves as the main battery pack) is removed, as shown by configuration list 401 b. Thus, the battery pack 2 (the oldest slave battery pack) becomes the new master battery pack, as shown in the configuration list 401 c. To complete the conversion, the battery pack 2 may request battery pack information from other battery packs so that the other battery packs can be appropriately instructed.

Subsequently, battery pack 5 is inserted into the battery system, which results in a new entry being added to configuration list 401d, where ID 243 is the same as the ID of previously removed battery pack 1. For the embodiment shown in fig. 4, the battery pack 5 may be a re-inserted old main battery pack or a new battery pack inserted into the battery system.

For some embodiments, battery pack information may be lost when the battery pack is removed from the battery system. When the battery pack is reinserted, the reinserted battery pack may obtain battery information from the configured battery pack. However, some embodiments may support memory persistence (e.g., flash) such that battery pack information is retained at the battery pack even when the battery pack is removed and reinserted.

Fig. 5 shows a flow chart 500 for configuring a plurality of battery packs according to an embodiment. At block 501, a battery pack is added to a battery system. If no other battery packs are connected to the communication channel, as determined at block 502, an entry is added at the top of the configuration list, and at block 504, the battery pack becomes the master battery pack. Otherwise, at block 503, the added battery pack is added to the bottom of the configuration list and becomes a slave battery pack.

At block 504, the battery pack is removed from the battery system. If the battery pack is the first member of the configuration list, as determined at block 505, the entry is removed at block 506 and the battery pack corresponding to the next entry is designated as the master battery pack at block 507. Otherwise, the entry for the removed battery pack is deleted at block 508.

Fig. 6A illustrates a general message flow scenario for configuring multiple battery packs according to the flowchart illustrated in fig. 5. The generic message represents a message supported by different communication channels, for example via a Controller Area Network (CAN) bus, ethernet, industrial ethernet, MODBUS or Bluetooth Low Energy (BLE) and/or the like.

The message flow in fig. 6A is based on a centralized approach, where the master battery pack maintains a configuration list and repeatedly (e.g., periodically) sends the configuration list to the other battery packs over the communication channel. However, embodiments (e.g., as shown in fig. 6D) may support a distributed approach in which each battery pack maintains its own configuration list locally and broadcasts the configuration list repeatedly over the communication channel. Because the battery pack receives all broadcasts from other battery packs, the battery pack can modify its own configuration list to be consistent with the configuration list broadcast by the other battery packs.

When battery 601 (battery 1) becomes the master battery at event 631, battery 601 sends periodic update messages 661a, 661b, 661c to battery 602, 603, and 604, respectively. If the message protocol supports a single broadcast message (e.g., with a global destination address) that is received and processed by all of the battery packs connected to the communication channel, then battery pack 601 only sends one message. Otherwise, battery 601 sends separate messages to battery 602, 603, and 604 (which are configured to be slave to the battery).

For some embodiments, messages 661a, 661b, 661c may be sent repeatedly, but not periodically.

Periodic update messages 661a, 661b, 661c may contain configuration information (e.g., configuration lists 401a, 401b, 401c, 401d as shown in fig. 4). For some embodiments, the battery pack 601 periodically transmits a broadcast message. However, if the battery pack 601 is removed (e.g., corresponding to event 632), the periodic transmission of update messages will be interrupted.

When the oldest slave battery pack (battery pack 602) detects an interrupt at event 633, battery pack 602 assumes the role of the master battery pack. Accordingly, the battery pack 602 removes the top entry of the configuration list (corresponding to the battery pack 601) and periodically sends the revised configuration list via update messages 662a, 662 b.

When battery pack 605 (battery pack 5) is added at event 634, battery pack 605 sends a join request 663 according to the SAE J1939 address declaration process. Thus, the battery pack 605 is added by the battery pack 602 (currently the master battery pack) at event 635, and the battery pack 602 periodically sends update messages 664a, 664b, 664c and update messages 665a, 665b, 665c.

Fig. 6B illustrates a message flow scenario on a CAN bus for configuring multiple battery packs according to an embodiment.

The CAN communication protocol (ISO-11898:2003) describes how information is transferred between devices on a network and conforms to the Open Systems Interconnection (OSI) model defined by layers. The actual communication between devices connected by a physical medium is defined by the physical layer of the model. The ISO 11898 architecture defines the lowest two layers of the seven-layer OSI/ISO model, referred to as the data link layer and the physical layer.

The CAN communication protocol supports a standard version (11-bit identifier field) and an extended version (29-bit identifier field). However, embodiments typically use standard versions, as the supported identifier space is typically large enough.

CAN buses are commonly referred to as broadcast type buses, wherein each message contains a source address (e.g., a device ID) rather than a destination address. Thus, all battery packs (corresponding to nodes) can "hear" all transmissions. The battery packs may selectively ignore the message, or may process the message by providing local filtering so that each battery pack may respond to the relevant message.

Embodiments may use data frame messages specified in the CAN protocol. The message type carries a payload of 0to 8 bytes, with the data fields (typically by software applications executing at the battery pack) being interpreted at the higher protocol layers. For example, the data field may convey SoC and/or SoH information when the slave battery pack sends status information back to the master battery pack.

To assign an identification value (address) to a battery pack, terminal device, or charger, embodiments may utilize industry standards such as SAE J1939 address declaration procedures. The SAE J1939 protocol is a higher protocol layer that builds on top of the CAN data link and physical layer.

Referring to fig. 6B, when battery pack 601 (battery pack 1) becomes the master battery pack at event 636, battery pack 601 sends periodic data frame messages 671 to battery packs 602, 603, and 604, respectively. The data frame message 671 corresponds to the periodic update messages 661a, 661b, 661c shown in fig. 6A (because the CAN protocol only supports source addresses, all battery packs CAN receive and process a single broadcast message sent via the CAN bus). The data frame message 671 contains at least a list of configurations in the payload.

When the battery pack 601 is removed (e.g., corresponding to event 637), the periodic transmission of the periodic data frame message is interrupted.

When the oldest slave battery pack (battery pack 602) detects the interrupt at event 638, battery pack 602 assumes the role of the master battery pack. Accordingly, the battery pack 602 removes the top entry of the configuration list (corresponding to the battery pack 601) and periodically sends the revised configuration list via the data frame message 672.

When the battery pack 605 (battery pack 5) is added at event 639, the battery pack 605 initiates an address declaration process 673 that declares its Identification (ID) value. When completed successfully, an entry with the identity of the battery pack 605 is added to the bottom of the configuration list by the master battery pack 602 at event 640.

The battery pack 602 (now the master battery pack) then periodically transmits a broadcast data frame message 674.

Fig. 6C illustrates a change in the message flow scenario illustrated in fig. 6B for configuring a plurality of battery packs according to an embodiment. As with fig. 6B, battery pack 601 (designated as the master battery pack at event 641) periodically sends the configuration list via message 681. However, acknowledgement messages 682a to 682c are returned from the battery packs 602, 603 and 604 to acknowledge receipt.

At event 642, the battery pack 604 is removed from the battery system. When the battery pack 601 periodically transmits the message 683, only the messages 684a to 684b are returned. Thus, a message timeout occurs at event 643 and master battery pack 601 detects that battery pack 604 has been removed and removes the entry for battery pack 604 from the configuration list. The modified configuration list is included in the next periodic broadcast.

Fig. 6D illustrates a variation of the message flow scenario illustrated in fig. 6B, wherein the configuration list is maintained in a distributed rather than centralized manner.

At event 644, battery 601 is distributed as a master battery. Each of the active battery packs 601 to 604 maintains its own configuration list and broadcasts the configuration list to the other battery packs via messages 691a to 691d via the CAN bus, instead of the master battery pack maintaining the configuration list and sending the configuration list to the other battery packs, with list_1, list_2, list_3 and list_4 corresponding to the configuration messages maintained at battery packs 601 to 604, respectively. If necessary, the battery packs 601 to 604 may modify their own configuration list to coincide with the configuration list broadcast by the other battery packs. For example, a battery pack may have recently been inserted into a battery system, and its configuration list may need to be revised to be consistent with the current configuration.

When the battery pack 601 is removed (e.g., corresponding to event 645), periodic transmission of periodic data frame messages from the battery pack 601 is terminated.

When the battery packs 602-604 detect termination at event 646, the battery pack 602 assumes the role of the master battery pack. Accordingly, the battery packs 602-604 remove the top entry of the configuration list (corresponding to the battery pack 601) maintained locally at the battery packs 602-604 and periodically send the revised configuration list via data frame messages 692 a-692 c.

When a battery pack 605 (battery pack 5) is added at event 647, the battery pack 605 initiates an address declaration process 693 that declares its Identification (ID) value. When successful, battery packs 602-604 add battery pack 5 to the bottom of the local copy of the configuration list. 605 at event 648, and then broadcast the revised configuration list via data frame messages 694a through 694 d. For one aspect of embodiments involving balancing, as will be discussed, the inrush of current between multiple lithium ion batteries in a large battery system is an undesirable phenomenon that occurs for lithium ion battery cells because large inrush currents may reduce the life of the lithium ion battery cells. This phenomenon may occur due to a large variation in SoC value between battery packs in the battery system. For example, when a brand-new lithium ion battery pack is added to a battery pack system, the capacity (e.g., energy level) of the brand-new lithium ion battery pack at the beginning of its new life may be significantly different from the capacity of the battery cells of the old battery pack that already exist in the battery pack system. Such energy level differences between the cells of the new battery and the cells of the old battery may damage other lithium ion battery cells in the battery system. This aspect relates to balancing techniques that utilize internal (not external) battery management systems and master-slave topologies.

As previously described, some embodiments order the configuration list based on the time the battery pack is connected to the communication channel (e.g., CAN bus). By this method, the oldest battery pack is designated as the master battery pack. However, other embodiments may use different approaches. For example, members of the configuration list may be ordered from top to bottom by decreasing the open circuit voltage value of the battery pack. When the discharge array of the battery pack is disabled (in other words, the battery pack is not discharged onto the power bus of the battery system), the open circuit voltage of the battery pack may be measured.

Each battery pack may share its measured open circuit voltage with other battery packs connected to the communication channel. Based on the measured open circuit voltage, a configuration list is maintained, with entries for each battery pack listed in descending order. The battery pack corresponding to the top entry has the maximum open circuit voltage and serves as the main battery pack of the battery system. For the exemplary embodiment, the battery system includes a first battery pack, a second battery pack, and a third battery pack having open circuit voltages V _open1、V_open2 and V _open3, respectively, where V _open2＞V_open3＞V_open1. The top entry of the configuration list is associated with the second battery (the main battery), followed by the entry of the third battery, and then followed by the entry of the first battery. Thus, if the second battery fails, the third battery will assume the role of the main battery.

For some embodiments, an ID is assigned to a battery pack in a battery system while an open circuit voltage is measured and stored in a configuration list. In the infrequent case where the open circuit voltages of the two battery packs are equal, one battery pack may be selected at random or one battery pack may be selected by the highest digital ID.

The configuration list may be updated when the battery pack is installed in the battery system. For example, a battery pack installed after the start of discharge will initially enter a standby mode (in which the discharge array is disabled) so that the open circuit voltage can be measured by the battery pack. The newly installed battery pack may then share the measured open circuit voltage with other battery packs via the communication channel. For some embodiments, the configuration list may then be updated with entries for newly installed battery packs based on the measured open circuit voltage. However, for some embodiments, the current configuration list may remain unchanged until the battery pack being discharged is disconnected from the battery system.

For some embodiments, the configuration list may be maintained centrally by the master battery pack. However, for some embodiments, each battery pack in the battery system may maintain a copy of its own configuration list based on information shared via the communication channel.

For one aspect of embodiments involving balancing, as will be discussed, the inrush of current between multiple lithium ion batteries in a large battery system is an undesirable phenomenon that occurs for lithium ion battery cells because large inrush currents may reduce the life of the lithium ion battery cells. This phenomenon may occur due to a large variation in SoC value between battery packs in the battery system. For example, when a brand-new lithium ion battery pack is added to a battery pack system, the capacity (e.g., energy level) of the brand-new lithium ion battery pack at the beginning of its new life may be significantly different from the capacity of the battery cells of the old battery pack that already exist in the battery pack system. Such energy level differences between the cells of the new battery and the cells of the old battery may damage other lithium ion battery cells in the battery system. This aspect relates to balancing techniques that utilize internal (not external) battery management systems and master-slave topologies.

According to one aspect of this embodiment, different balancing techniques for lithium ion battery cells may be supported in a large battery system. For example, this aspect includes three balancing techniques: "Intelligent converter balancing", "begin direct balancing" and "begin interleaved balancing", which may be used in medium and large battery pack embodiments to ensure safe use and life of lithium ion battery cells. This aspect may utilize a converter (with battery pre-charge circuitry) to charge balance each battery pack to prevent and/or limit inrush current, over-current faults, and/or short circuit faults.

Fig. 7A illustrates a flow chart 700 for determining a balance type for a plurality of battery packs according to an embodiment.

At block 701, the master battery pack transitions from a sleep state. For example, when the terminal device is not in use, the main battery pack may periodically wake up to determine whether there is a change in the operating state.

At block 702, a master battery pack determines a number of battery packs installed in a battery system. For example, the master battery pack may verify that all battery packs on the confirmation list are active on the communication channel.

At block 703, the master battery pack confirms how many battery packs are needed for operation of the device. For example, the master battery pack may confirm the number of battery packs needed by a predefined calibration or a system provided message.

At block 704, the master battery pack determines whether a minimum number of battery packs (including itself) are installed based on the power requirements of the device (e.g., obtained from the terminal device via the communication channel).

If there is not a minimum number of available battery packs to properly power the terminal device, then at block 705, the configured battery pack is prevented from discharging by the master battery pack commanding the slave battery packs (and themselves) to open the corresponding discharge arrays. At block 706, a fault indicator is activated indicating that sufficient battery packs are not installed to power the terminal device. If an additional battery pack is installed at block 707, the fault indicator is cleared at block 708. If the terminal device is activated or otherwise enabled (e.g., the key is in the "on" position) at block 709, process 700 returns to block 704. Otherwise, process 700 returns to block 701.

Returning to block 704, when the master battery pack determines that there are a sufficient number of battery packs, the master battery pack collects battery pack information (e.g., soC, soH, and voltage information) from each of the slave battery packs and collects its own battery pack information at block 710. For example, as will be discussed in further detail, the master battery pack may send a "request battery pack information" message to each of the configured slave battery packs, and receive a "battery pack information" message from each slave battery pack in response to the requested information.

At block 711, the master battery pack determines from the collected SoC data whether balancing is required. For example, some battery packs may have a high SoC, while some may have a low SoC. By balancing the battery packs, a sufficient number of battery packs may be used to properly discharge in order to power the terminal device.

If balancing is not required, the battery system may be discharged to power the terminal device at block 717.

If balancing is desired, the type of balancing is determined at block 712. As will be discussed in more detail, embodiments may support three different types of balances: converter balancing (block 713), direct balancing (block 714), and interleaved balancing (block 715).

Tables 1 and 2 present examples of balances according to embodiments.

The above examples illustrate that the type of balancing may vary when the battery is balanced. For example, according to table 1, the balance type is changed from converter balance to interleaved balance, and according to table 2, the balance type is changed from converter balance to direct balance.

After balancing, as determined at block 716, if the number of battery packs is available for discharging, the terminal device may be powered at block 717. Otherwise, the battery pack may be rebalanced based on revised SoC values obtained from the previous balancing.

When rebalancing occurs, as determined at block 716, the rebalancing may utilize a different type of balancing than previously used. For example, the converter balancing may be applied first, and the subsequent rebalancing may utilize interleaved balancing.

Fig. 7B expands block 712 of fig. 7A for determining the type of charge balance. For example, embodiments may support multiple balancing types, such as direct balancing, converter balancing, and interleaved balancing as previously discussed.

At block 721, if the variability of SoC values between battery packs is small enough, then at block 722 the battery system can power the terminal device. (e.g., the SoC difference between all battery pack pairs is less than a predetermined threshold.) otherwise, process 712 continues with balancing the battery packs.

Block 723 identifies the battery pack with the highest SoC value so that the identified battery pack may be discharged, thereby providing charge to other battery packs during balancing.

At block 724, process 712 determines whether direct balancing cannot be applied (e.g., when the SoC difference between the highest SoC battery pack and the identified battery pack is above a predetermined SoC threshold). If so, then at block 728 converter balancing is applied to the identified battery pack (where the highest SoC battery pack is discharged onto the power bus and the identified battery pack is charged through the power bus via its converter). When the converter balancing is complete, process 712 may return to block 721 and determine whether balancing may be applied to different combinations of battery packs, where the balancing types may be the same or different (e.g., direct balancing or interleaved balancing).

Referring back to block 724, if direct balancing can be applied (e.g., when the SoC difference between the highest SoC battery pack and the identified battery pack is below a predetermined SoC threshold), process 712 determines at block 725 whether converter balancing can be applied to one or more other battery packs. If so, then at block 727 interleaved balancing is applied to the highest SoC battery pack, the identified battery pack, and one or more other packets. Otherwise, at block 726, direct balancing is applied between the highest SoC battery pack and the identified battery pack.

Fig. 7C shows a flowchart 730 for determining a balance type for a plurality of battery packs according to an embodiment.

Table 3 shows the relationship between the operating mode of the battery system and the safety interlock pin (indicator) and the wake-up pin (indicator). For example, the safety interlock pin is "on" when the battery pack is properly inserted into the battery system (as sensed by the interlock connection through the battery pack connector), and the wake-up pin is "on" when the user turns the key to activate the powered appliance (terminal device).

When in the off (sleep) mode, the discharge and charge arrays of the battery pack are disabled and the battery pack consumes only enough power so that the battery pack can transition to another state (e.g., a balanced mode) when the battery pack detects an appropriate signal (e.g., a wake-up indicator).

For some embodiments, as shown in table 3, the battery system may support multiple modes of operation: disconnect (sleep), balance and charge/discharge. Although a single mode for charging/discharging is shown, charging and discharging are separate operations based on interactions of the battery system with its external environment. For example, when the wake-up indicator and the safety interlock indicator are on, and if a charger (typically external to the battery system) is sensed via the CAN bus, the battery system enters a state of charge. However, if the battery system senses the terminal device (e.g., appliance), the battery system enters a discharge state. As will be discussed in further detail, the battery system may support "smart charging" when in a charging mode and "smart discharging" when in a discharging mode.

FIG. 7C is similar to FIG. 7A; however, according to the relationships shown in table 3, process 730 includes interactions with sleep, balance, and charge/discharge modes. At block 731, the battery system enters a sleep mode when the safety interlock indicator is not detected. Otherwise, the battery system (typically by the master battery pack) gathers configuration information (e.g., soC information about the different battery packs). At block 732, the battery system determines whether a wake-up indicator is detected. If not, the battery system enters a balancing mode. Otherwise, the battery system enters a charge/discharge mode.

Fig. 8 illustrates a message flow scenario 800 for determining a balancing type for a plurality of battery packs based on flowchart 700 and in accordance with an embodiment. The master battery pack 802 confirms the availability of battery packs 803 and 804 corresponding to messages 861a, 861b, 862, and 863 at event 851 based on the entries of the current confirmation list. As previously described, embodiments may support different messaging protocols. For example, according to the CAN protocol, the data frame message may contain data in a data field indicating an acknowledgement request or an acknowledgement response. As described above, the interpretation of the data is based on application software executed at the terminal device 801 and the battery packs 802 to 804.

The terminal device 801 provides its power requirements in message 864 so that the main battery 801 can determine the number of battery packs required by the terminal device 801 at event 852.

At event 853, the master battery pack 802 collects SoC data about the other battery packs via messages 865-868. (the master battery pack 802 may use internal messaging within the battery pack to obtain SoC information about itself.) for example, according to the CAN protocol, the data contained in the request battery pack information message 865 may be interpreted as a request from the target battery pack, while the data in the battery pack information message 866 may be interpreted as requested data (e.g., soC data) from the target battery pack.

Based on the collected SoC data, the master battery pack 801 determines the type of balancing required (if needed) and initiates the appropriate balancing process (e.g., the processes shown in fig. 9, 11, and 13).

As previously described, embodiments may support different types of balancing, such as: converter balancing, direct balancing, and interleaved balancing. Converter balancing generally requires a longer period of time than direct balancing.

Although the processes shown in fig. 9, 11 and 13 are typically performed at the main battery pack, the main battery does not need to be changed or discharged during balancing. This determination is based on the SoC values of battery cells 203 and 210 (shown in fig. 2A and 2B, respectively) rather than whether the battery pack is a master battery pack or a slave battery pack.

Fig. 9 shows a flowchart 713 (refer to fig. 7A) for converter balancing a plurality of battery packs according to an embodiment. Block 901 begins converter balancing, where one of the battery packs (either the master battery pack or one of the slave battery packs) charges one or more of the other battery packs.

With the converters balanced, the charge of a single battery is transferred to one or more battery packs via the converters on each of the charged battery packs. Thus, this type of balancing involves two or more battery packs.

Although not explicitly shown, the master battery pack collects SoC data about all battery packs including itself. For example, the master battery pack may request battery status information from other battery packs via the CAN bus and internally acquire its own SoC data.

At block 902, the master battery pack enables the battery pack with the highest SoC for discharge by enabling the discharge array. By enabling the charging array and the on-board converter, the master battery pack also enables one or more of the battery packs having the lowest SoC to accept charge from the discharging battery pack.

At block 904, the master battery pack obtains SoC values from the battery packs described above, and continues the balancing process at block 905 until a desired charge balance is obtained at block 905. If the charge balance is sufficient, the battery pack may be used to power the terminal device. However, a faster balancing mode (e.g., direct balancing as will be discussed) may be applied later.

Fig. 10 illustrates a message flow scenario for converter balancing multiple battery packs according to an embodiment. The battery packs 1002, 1003, and 1004 initially have SoC values of 100%, 65%, and 65%, respectively. As previously described, the master battery pack 1002 may obtain the SoC value by requesting battery status information and receiving the status information via a data frame message on the CAN bus.

At event 1051, master battery pack 1002 determines that battery packs 1003 and 1004 are to be charged by themselves (battery pack 1002). To this end, the master battery pack enables its own discharge array and enables the charge array and converter via messages 1061 and 1062. Balancing continues at event 1052 until the desired balanced charge (80%, 75%, and 75%) is obtained. At this point, balancing ends, causing the master battery pack to disable its charging array, and disabling the charging arrays and converters of battery packs 1003 and 1004 via messages 1063 and 1064.

Fig. 11 shows a flow chart 714 for directly balancing a plurality of battery packs according to an embodiment. As shown in fig. 7A, when process 700 determines that direct balancing should be performed, the master battery pack initiates direct balancing at block 1101.

By direct balancing, one of the battery packs charges the other battery pack through a low impedance electrical path. Thus, only two battery packs relate to the balancing type.

Although not explicitly shown, the main battery pack acquires SoC values of all the battery packs mounted in the battery system. To this end, the master battery pack sends a status request to the slave battery pack, and receives status information (e.g., soC value) from the slave battery pack via messaging over the communication channel. However, because the main battery knows its own battery cell status, only internal messaging for the main battery is required.

At block 1102, the master battery pack commands the battery pack with the higher SoC to begin discharging by enabling its discharge array, and at block 1103, the master battery pack commands one of the battery packs with the lower SoC to begin charging by enabling its charge array.

At block 1104, the master battery pack collects SoC data from the battery packs that are charge balanced. When an acceptable SoC is reached at block 1105, direct balancing is terminated at block 1106.

Fig. 12 illustrates a message flow scenario for directly balancing multiple battery packs according to an embodiment. The master battery (battery 1201) collects initial SoC values 80%, 70% and 90% for battery 1201, 1202 and 1203, respectively.

Because battery 1202 has the lowest SoC and battery 1203 has the highest SoC, the master battery commands battery 1202 to enable its charge array and battery 1203 to enable its discharge array via messages 1261 and 1262, respectively.

When the SoC value of the battery packs 1202 and 1203 reaches 80%, the master battery pack (battery pack 1202) determines that direct balancing is complete at event 1251 and therefore disables the charge and discharge arrays via messages 1263 and 1264, respectively.

Fig. 13 illustrates a flow chart 715 for cross balancing multiple battery packs according to an embodiment. As shown in fig. 7A, when process 700 determines that interleave balancing should be performed, the master battery pack initiates interleave balancing at block 1301.

The staggered balancing utilizes an algorithm to directly balance. By staggering the balancing, one of the battery packs (typically the highest SoC value) directly charges the other battery pack with a lower SoC while one or more other battery packs with lower socs are charged by the converter balancing (with the converter located on the charged battery pack being enabled). In order to keep other lower SoC battery packs within acceptable limits, the direct balancing may be switched to a different lower SoC battery pack, while the previous lower SoC battery pack is now balanced via the converter.

Similar to blocks 1101 and 1102 shown in fig. 11, at blocks 1301 and 1302, direct balancing is established with the battery pack having the highest SoC and another battery pack having a low SoC in the group. However, at block 1304, converter balancing is established with some or all of the battery packs in the low SoC group.

At block 1305, the master battery pack collects updated SoC values of the participating battery packs. When the directly charged battery reaches the determined SoC threshold (e.g., when an imbalance occurs in one battery in the low SoC group), a direct balance is established with another battery in the low SoC group at block 1307.

When all of the battery packs are within an acceptable SoC range, as determined at block 1308, the interleaving balance is terminated at block 1309.

Fig. 14 and 15 illustrate message flow scenarios for cross balancing multiple battery packs according to embodiments. The master battery (battery 1401) collects initial SoC values 60%, and 100% of the battery 1401, 1402, and 1403, respectively.

At event 1451, master battery 1401 initiates direct balancing between battery 1402 (in a low SoC group) and battery 1403 (highest SoC) and establishes converter balancing between battery 1403 itself (also in a low SoC group). Thus, master battery 1401 sends messages 1461 and 1462 corresponding to battery 1461 and 1462, respectively, over a communication channel and generates any internal messaging as needed to enable its charging array and converter.

As a result of the balancing, soC values of the battery packs 1401, 1402, and 1403 become 62%, 70%, and 88%, respectively. Due to the charge imbalance between battery 1401 and battery 1402, master battery 1401 establishes a direct balance between battery 1403 and itself, and establishes a converter balance for battery 1402. Thus, at event 1452, master battery 1401 instructs battery 1402 to enable its converter via message 1463 (such that charging now occurs via the converter rather than directly), and to disable its own converter such that its battery cells are directly exposed to charging.

Referring to fig. 15, soC values of battery packs 1401, 1402, and 1403 become 72%, and 76%, respectively, as a result of balancing. At event 1453, master battery 1401 determines that balancing has been completed and terminates staggered balancing by sending messages 1464 and 1465 to battery 1403 and 1402, respectively, and disables its charging array internally.

Referring to fig. 15, soC values of battery packs 1401, 1402, and 1403 become 72%, and 76%, respectively, as a result of balancing. At event 1453, master battery 1401 determines that balancing has been completed and terminates staggered balancing by sending messages 1464 and 1465 to battery 1403 and 1402, respectively, and disables its charging array internally.

The intelligent system and algorithm method (e.g., process 1700 as shown in fig. 17) may ensure that socs corresponding to multiple battery packs may become more balanced, for example, to ensure that the multiple battery packs may be charged together. In various embodiments, the battery pack may include one or more batteries and/or may include a device that may include one or more batteries. One or more cells of a battery pack may share various characteristics (e.g., state of charge, state of health, etc.). Furthermore, each battery pack may be enabled or disabled, for example, in terms of its ability to charge or discharge other battery packs or terminal devices.

Still referring to fig. 16, a battery pack with a large SoC variation cannot be immediately connected to the charger 1601. For example, as shown in fig. 16, battery packs 1602a and 1603a, each having a lower SoC (e.g., 20% and 20%, respectively) than the other battery packs, may be charged earlier (e.g., before the other battery packs) until a set threshold may be reached at which a battery pack having a higher SoC (e.g., battery pack 1604 b) may be charged. For example, it may be necessary to charge a battery pack having a lower SoC preferentially before charging a battery pack having a higher SoC because if this is not done, charging a higher battery pack having a higher SoC first may cause a fast inrush current to a lower SoC battery pack. In some aspects, the systems and devices presented herein may enable charging of various battery packs by enabling flow of a discharge array between a charger and a respective battery pack.

As shown in fig. 16, battery packs 1602a and 1603a are initially charged such that their socs increase from 20% to 40% (e.g., as shown in fig. 1602b and 1603 b). Charging of battery packs 1602 b-1604 b may continue until the SoC level of battery pack 1605b is reached. At this time, the battery pack 1605b may be activated so that charging of the battery packs 1602b to 1605b may continue.

Fig. 17 shows an example flowchart of a method 1700 for charging a plurality of battery packs according to an embodiment. The method 1700 may be performed by a computing device having one or more processors that may be communicatively linked to one or more of a plurality of battery packs and/or to a charger. Also or alternatively, a computing device performing method 1700 may include a battery (e.g., a "master battery" or "master battery") having the ability to manage one or more functions of other battery(s) of the plurality of battery(s). After acquiring SoC values for battery packs in the battery system, at block 1701, a subset of the battery packs may be grouped into lower SoC groups. For example, the acquired SoC values (e.g., soC readings) may be classified into various levels, e.g., based on a predetermined range. Those battery packs having the lowest SoC values may be grouped to the lowest level. The battery packs within a certain level may have SoC values within a certain or predetermined range of each other. Those battery packs having a second lowest SoC value (e.g., a SoC value above the lowest level but below the SoC values of the remaining battery packs) may be placed at the second lowest level. As used herein, "lower SoC battery" may refer to a battery that includes a list of: (1) A group of battery packs having a lowest level of SoC values, and (2) a group of battery packs having a second lowest level of SoC values.

At block 1702, a SoC threshold may be determined. The SoC threshold value may be approximately equal to the SoC value of a group of one or more battery packs having SoC values just above the group of battery packs having the lowest SoC value. For example, the SoC threshold value may be based on a second lowest level SoC value (e.g., an average of SoC values of a second lowest level battery pack).

At block 1703, the battery of the group with the lowest level SoC may be enabled for charging, e.g., to facilitate charging of the battery of the lowest level SoC. In some aspects, if one or both of the safety interlock pin or the wake-up pin is set to "on," charging may be enabled, as previously described.

When the SoC value of the charged battery reaches the SoC threshold, as determined at block 1704, process 1700 may include determining whether to expand the list (e.g., the "lower SoC battery" list of step 1701) for subsequent charging at block 1705. Determining whether to expand the list may be based on whether there is significant variability in the SoC of the battery pack (e.g., whether the SoC variability of the battery pack meets a SoC variability threshold), as will be further described with respect to fig. 18C. If the list is to be enlarged, the SoC threshold may be updated (e.g., based on determining a second lowest level of socs in the updated list), the selected battery pack may be enabled, and charging may continue at blocks 1706 and 1707.

Fig. 18A shows a message flow scenario for charging multiple battery packs of the example shown in fig. 16. In this scenario, charger 1801a may perform one or more iterations of: the method includes collecting SoC data (e.g., receiving SoC readings) from a plurality of battery packs (e.g., battery packs 1802 a-1805 a), identifying SoC levels to form a list based on the SoC levels, and enabling charging the selected battery pack to a SoC threshold via a communication channel (e.g., CAN bus). For example, at event 1851a, charger 1801a may collect initial SoC values of 20%, 40%, and 60% from battery packs 1802a, 1803a, 1804a, and 1805a, respectively.

At event 1851b, charger 1801a may determine that the group of battery packs having the lowest level of SoC values includes battery packs 1802a and 1803a, and the group of battery packs having the higher (e.g., second lowest) level of SoC values includes battery pack 1804a. A battery pack list may be formed and may include battery packs at a lowest level of SoC and battery packs at a higher level (e.g., a second lowest level) of SoC.

At event 1851c, charger 1801a may enable charging of the group of batteries (e.g., batteries 1802a and 1803 a) having the lowest level of SoC value via messages 1861 and 1862. The charging may continue until the SoC values of the battery packs meet the SoC threshold based on the group of one or more battery packs having a higher SoC value (e.g., the battery pack having the second lowest level of SoC values (e.g., battery pack 1804a is 40%)).

At event 1852a, charger 1801a may collect SoC values for all battery packs. As shown in fig. 18A, the SoC value of battery packs 1802a and 1803a will increase to 40% as a result of the aforementioned charging at event 1851 c. At event 1852b, charger 1801a may determine to extend the list of battery packs determined at event 1851 a. For example, soC variability may be determined for battery packs 1802 a-1805 a, and the list may be expanded based on SoC variability that is significant enough to meet the SoC variability threshold. In the scenario shown in fig. 18A, battery 1806a has a 60% SoC value that is different from the updated SoC values of battery 1802a, 1803a, and 1804a by 40%. Thus, battery packs 1802a, 1803a, 1804a, and 1805a exhibit SoC variability, which may cause charger 1801a to expand the list. The expanded list may include a group of one or more battery packs (e.g., battery packs 1802a, 1803a, 18004 a) with the lowest level of SoC values that are updated and a group of one or more battery packs (e.g., battery pack 1805 a) with higher levels of SoC values that are updated. Thus, the previous group (e.g., the group of battery packs having the lowest level of SoC values) may include battery pack 1804a. Thus, at event 1852c, charger 1852c may enable charging of battery packs 1802a, 1803a, and 1804a via message 1863.

Fig. 18B illustrates an example message flow scenario for charging multiple battery packs of the example shown in fig. 16. However, when charger 1801b is detected via connection indicator 1871, main battery 1802b collects SoC data and enables the battery, rather than charger 1801b collecting SoC data and enabling the battery. The connection indicator 1871 may be obtained by different methods including messaging through a communication channel, pin, or the like.

Fig. 18C shows an example flowchart of a method 1800C for intelligently charging a plurality of battery packs, according to a non-limiting embodiment. Method 1800C may be performed by a computing device having one or more processors. The computing device may be a stand-alone device communicatively linked to one or more of the battery packs and/or the charger. Also or alternatively, the computing device may include one of the battery packs (e.g., the master battery pack) having the ability to manage one or more functions of the other battery packs of the plurality of battery packs. Also or alternatively, the computing device may include a charger.

As previously discussed, each battery pack may have a state of charge (SoC) that indicates, for example, a degree or level of charge relative to its capacity. At step 1874, the computing device may receive a reading (e.g., a first reading) of the SoC of each of the plurality of battery packs. Readings may be taken via sensors or monitors at each battery pack. As previously described, the SoC may vary among multiple battery packs or may remain relatively constant. The SoC variability (e.g., first SoC variability) may be calculated to indicate the degree of variability of the socs of the plurality of battery packs (e.g., as in step 1875).

The SoC variability may be based on the SoC of each of the respective battery packs acquired in step 1874. For example, the SoC variability may be based on one or more of the following: variance, standard deviation, range (e.g., quarter bit difference), mean absolute difference, median absolute deviation, mean absolute deviation, distance standard deviation, or similar measure of SoC value based on each of the plurality of battery packs. For example, in table 1 discussed above including multiple battery packs (e.g., battery pack 1, battery pack 2, battery pack 3, and battery pack 4), the SoC variability at time T0 is greater than the SoC variability at time T6. In one aspect, in the case of determining SoC variability based on a calculated SoC value range, the SoC variability of the battery pack at T0 is 85 (i.e., 100% to 15%), while the SoC variability at T6 is only 4 (e.g., 45% to 41%). If "5" is set to the SoC variability threshold, then the SoC variability at T6 can be said to have met (e.g., fallen below) the threshold.

In some aspects, interlocking the safety pin may be required to allow interaction with the battery pack to occur before the computing device can receive SoC readings. For example, the computing device may initially determine that the interlock safety pin allows SoC readings to be received from multiple battery packs.

The computing device may store, for example, in the storage device 202, metrics indicating a variability threshold of the SoC, for example, to indicate whether the variability of the SoC is insignificant. For example, if the SoC of a battery pack (e.g., a first battery pack) is significantly lower than the SoC of another battery pack (e.g., a second battery pack), the SoC variability is likely to be large and thus the SoC variability threshold is not met. Thus, at step 1876, the computing device may determine whether the SoC variability (e.g., as calculated in step 1875) meets the SoC variability threshold.

If the SoC variability does not meet the SoC variability threshold (e.g., the variation of the SoC between the multiple battery packs is significant), the computing device may establish the SoC threshold (e.g., as in step 1878). The SoC threshold may be based on SoC readings of a battery pack (e.g., a second battery pack) having a next higher SoC reading after the battery pack (e.g., a first battery pack) having the lowest SoC. Thus, the computing device may identify the lowest SoC reading in order to determine the next higher SoC reading (e.g., as in step 1877). For example, as discussed with respect to fig. 16, battery pack 1604a has a 40% SoC, which is the next higher SoC after the lowest SoC of the battery packs belonging to battery packs 1602a and 1603a is 20%. Therefore, based on the example shown with respect to fig. 16, the SoC threshold value may be set to 40%.

Further, at step 1879, the computing device may charge a battery pack having a SoC that is lower than the established SoC threshold, for example, by enabling a charge array from the charger to the battery pack. The charging may cause the SoC of the battery pack to increase, for example, to cause it to approach, match, and/or meet SoC thresholds.

In some aspects, a wake pin as previously discussed may be required to allow charging to occur before the computing device can cause charging of any battery pack. For example, the wake-up pin may need to be set to "on" before charging occurs. The computing device may initially determine that the wake-up pin is set to "on" prior to causing the battery pack to charge.

This may be detected by the computing device via additional readings (e.g., second readings) of the SoC of each of the plurality of battery packs. Further, the computing device may determine or calculate a second SoC variability for the plurality of battery packs based on the additional readings. The second SoC variability may be found to meet the SoC variability threshold.

If the second SoC variability is not found to meet the SoC variability threshold, one or more steps of method 1800C may be repeated until the SoC variability threshold is met. For example, a new SoC threshold may be set based on the next higher SoC after the lowest SoC and cause the battery pack with the lowest SoC to be charged.

Thus, after the updated SoC variability of the plurality of battery packs meets the SoC variability threshold, one or more iterations of: the computing device may identify an nth group of one or more battery packs within the plurality of battery backup devices, wherein the nth group may have a lowest level of previous readings of the SoC of the plurality of battery packs; the computing device may also identify an (n+1) th group of one or more battery packs of the plurality of battery back-up devices, wherein the (n+1) th group may have a second lowest level of previous readings of the SoC of the plurality of battery packs; and the computing device may generate a list including the nth group and the n+1th group. In each iteration, the computing device may determine that the SoC variability of the list in the current iteration does not meet the SoC variability threshold. If the SoC variability does meet the SoC threshold, the computing device may exit the iterative loop. However, assuming that the SoC variability at each iteration does not meet the SoC variation threshold, the computing device may use the SoC threshold of the previous reading of the n+1th group of socs. Subsequently, the computing device may cause, via the charge array, charging of the nth group of battery packs to cause the SoC of the nth group to increase and meet the SoC threshold. The computing device may receive subsequent readings of the SoC for each of the plurality of battery packs. Thus, updated SoC variability for the plurality of battery packs may be determined based on subsequent readings of the SoC for each of the plurality of battery packs. As discussed, the above steps may be repeated until the SoC variability (updated at each iteration) meets the SoC variability threshold (e.g., the SoC of the battery pack varies less than a specified range).

Fig. 19A and 19B below show two examples of battery systems for powering a terminal device based on the power requirements of the terminal device. In fig. 19A, only one battery pack is needed to power the terminal devices 1901a, 1901B, while in fig. 19B, more than one battery pack is needed to power the terminal devices 1911a, 1911B.

Fig. 19A shows an example in which a plurality of battery packs are discharged to supply power to a terminal device according to an embodiment. Initial SoC values for battery packs 1902 a-1905 a are 40%, and 60%, respectively. As shown in fig. 19A, a single battery pack (e.g., battery pack 1905a with a 60% SoC) may be initially used to power terminal device 1901a until the SoC value of the single battery pack reaches 40% (the same SoC value as the other battery packs) (e.g., as in battery pack 1905 b). Only the group of one or more battery packs with the highest or higher SoC level (in this case the single battery pack 1905 a) is used to initially power the terminal device until the SoC value of the group reaches the SoC value of the rest of the group, which may be a more efficient and/or safe method of powering the terminal device with the battery pack. As shown in fig. 19A, after a single battery pack having an initially higher SoC value has been used to initially power the terminal device and its SoC reading reaches the reading of the other battery packs (e.g., battery packs 1902b through 1905 b), the other battery packs may join in powering the terminal device 1901 b.

Fig. 19B shows another example of discharging a plurality of battery packs to power a terminal device according to an embodiment. As shown in fig. 19B, the initial SoC values of the battery packs 1912a to 1915a are 40%, 40% and 60%, respectively. In some aspects, more than one battery pack may be required to power the terminal devices 1911 a-1911 b. In such aspects, the various systems and methods presented herein may be used to balance the battery pack prior to powering the terminal devices 1911 a-1911 b. Balancing of the battery packs 1912a to 1914a may be performed, for example, to prevent the risk that an undesired current inrush from the battery pack 1915a may occur without balancing. When balancing is achieved, the battery packs 1912b to 1915b may then power the terminal device 1911 b.

When powering a terminal device (e.g., a machine), connecting a battery pack with a varying SoC can be problematic. Thus, to prevent such problematic situations, a process (typically implementing intelligent methods) may be required to ensure that the required number of battery packs are connected for system discharge and are enabled when appropriate.

In general, when a plurality of battery packs are required to power a terminal device, it is preferable not to connect battery packs having a large SoC variation at the same time. Instead, balancing of the battery pack may be initially performed.

The discharge may first use one or more battery packs having a higher SoC value until a set threshold for a lower SoC battery pack is exceeded, at which the lower SoC battery pack may be enabled.

The process 2000 and process 2010 shown in fig. 20A and 20B, respectively, are based on the above criteria.

Fig. 20A shows a process 2000 for discharging a plurality of battery packs to power a terminal device. At blocks 2001-2003, initial SoC values for the battery pack are collected and balancing may be performed based on SoC changes and power requirements of the terminal device. As previously discussed, fig. 19B is an example illustration of a process of balancing a battery pack as described in blocks 2001-2003. However, as will be described in blocks 2004-2008, some aspects of the present disclosure may involve initially powering the terminal device through a single or limited number of battery packs having a higher SoC level before other battery packs may participate in powering the terminal device. As previously discussed, fig. 19A is an example illustration of a process of powering a terminal device through an initial limited number of battery packs and by expanding a list of backup batteries that may power the terminal device.

Referring now to block 2001a, the power requirements of the terminal device may be obtained and a first reading of the SoC of each of the plurality of battery packs may be obtained. The plurality of battery packs may include various battery packs or groups of battery packs having varying SoC values. At block 2001b, soC variability may be calculated to determine the extent of SoC value variation among multiple battery packs. Also or alternatively, a highest SoC level may be identified, and the computing device may determine that not all battery packs have SoC values of the highest SoC level.

According to SoC variability, multiple battery packs may pose a risk if they are used to power the terminal device at the same time. As previously discussed with respect to fig. 19A, if a group of one or more of the plurality of battery packs has a SoC value that is significantly greater than the level of the SoC of the remaining battery packs of the plurality of battery packs, it may be suggested to initially power the terminal device using only the group having the significantly greater SoC value (e.g., without being simultaneously powered by the other battery packs of the plurality of battery packs). The computing device may allow a group of a single or limited number of battery packs to power the terminal device by enabling only the corresponding discharge array of the group. The paths that allow the group to power the terminal devices are shown in blocks 2004 to 2008.

Another way to address the above and similar risks may be to balance the battery packs, reducing SoC variability for multiple battery packs, as previously discussed with respect to fig. 19B. For example, one group (e.g., a first group) of battery packs may have SoC values at a lower level than another group (e.g., a second group) of battery packs. Based on the change in SoC between the first group and the second group, the SoC variability of the plurality of devices may be calculated and found to not meet the SoC variability threshold (e.g., the range between the highest SoC value and the lowest SoC value is too large). Accordingly, the computing device may determine that balancing is required based on the SoC variability not meeting (e.g., falling within) the SoC variability threshold (e.g., "yes" at block 2002). Thus, the battery pack may be balanced according to the previously discussed method shown in fig. 19B.

Accordingly, the computing device may determine whether balancing is not required (e.g., "no" at block 2002). The decision may be a preference provided (e.g., configured) to the computing device by an operator of the computing device. Also or alternatively, the decision may be based on two or more SoC variability thresholds. For example, if the SoC variability of the plurality of battery packs is higher than a higher SoC variability threshold (e.g., a first SoC variability threshold), a path balancing the battery packs may be triggered. If the SoC variability is not above the first SoC variability threshold but is still above the second SoC variability threshold (which is not as high as the first SoC variability threshold), the paths depicted in blocks 2004-2008 may be triggered (e.g., such that one or more battery packs with higher socs initially power the end device).

Referring now to blocks 2004 through 2005, a group of one or more battery packs may be identified and enabled (e.g., by enabling a corresponding discharge array) to power a terminal device. The group may be identified by identifying the battery pack that is at the highest level or at least at a higher level than the other battery packs. Thus, the computing device may cause the group to power the terminal device, thereby initiating discharge of the group of battery packs (e.g., as in block 2005). Groups of discharged battery packs may reach lower SoC levels. The resulting lower SoC level of the group initially having the higher SoC level may result in lower SoC variability of the plurality of battery packs. Accordingly, the computing device may determine updated SoC variability at block 2006. If the updated SoC variability fails to meet the SoC variability threshold (e.g., there are still battery packs with higher SoC levels), then at blocks 2004-2005 additional battery packs may be similarly identified and enabled to power the terminal device. After the SoC variability of the plurality of battery packs meets the SoC variability threshold (e.g., there is not much change in SoC level of the plurality of battery packs), the computing device may allow all battery packs to power the terminal device.

Also or alternatively, the two paths described above (e.g., blocks 2002-2003 and 2004-2008, respectively) may be combined. For example, after balancing has been performed at block 2003, a second reading of the SoC of each of the plurality of battery packs may be taken and a second SoC variability may be calculated. The SoC variability may meet a SoC variability threshold, e.g., the socs of multiple battery packs may vary less and/or have a reduced range. Subsequently, a plurality of battery packs may simultaneously supply power to the terminal device.

Fig. 20B illustrates a process 2010 for discharging a plurality of battery packs according to an example embodiment. Process 2010 is similar to process 2000; however, some battery packs may be isolated based on their state of health (SoH). A battery pack with low SoH can be isolated and used only when needed.

At blocks 2011-2013, soC values and SoH values of the battery pack may be collected. A battery pack having a SoH value that does not meet a predetermined SoH threshold may be isolated so as to be enabled after the non-isolated battery pack has been used. A non-isolated battery (e.g., a battery having a SoH level that meets the SoH threshold) may be used to initially power the terminal device based on the terminal device requirements and the SoC value of the battery, as explained herein.

For example, at block 2013, a battery pack having a SoC value that meets the SoC threshold (e.g., the SoC value is higher than a next highest SoC level in the plurality of battery packs) may be enabled to power the terminal device, discharging the battery packs at block 2014. As indicated by blocks 2014-2016, the enabled battery pack may discharge until a lower SoC value is reached (e.g., the SoC fails to meet the SoC threshold). At this point, additional non-isolated battery packs may be enabled at block 2017. However, when no non-isolated battery packs are available, isolated battery packs may be considered at blocks 2018-2020.

Isolating low SoH batteries may be beneficial because the use of older batteries (typically associated with low SoH values) may be reduced, thereby extending the life of these batteries.

Fig. 21 shows a message flow scenario for discharging a plurality of battery packs of the example shown in fig. 19A. The battery packs 2002 to 2005 initially have SoC values of 40%, 40% and 60%, respectively. The power requirements of the terminal device 2101 may be retrieved from the main battery 2102 via a message 2161 on a communication channel (e.g., CAN bus), where only one battery is needed to power the terminal device 2101. Thus, according to process 2100, master battery 2102 can enable battery 2105 to discharge via message 2162.

When battery 2105 reaches the SoC value of the other battery, master battery 2102 enables battery 2103 and 2104 via messages 2163 and 2164, and may enable itself via internal messaging.

In some aspects, a process (e.g., process 2200 as will be discussed) may involve a "limp home" mode of operation when a lithium-ion battery cell fails in a large battery system. The "limp home" mode of operation may safely mitigate catastrophic failure in the system. For example, the voltage of the battery cell may become very low (e.g., below a predetermined voltage threshold), which indicates that the battery cell is malfunctioning. For medium-to-large battery pack embodiments, the internal battery management system may diagnose the fault in advance, and thus may mitigate the fault by initiating a partial shutdown of the battery pack, so that the devices (end devices) powered by the battery system do not need to be completely shut down and may still "limp home".

Fig. 22 is a flow chart for limp home mode operation according to an embodiment. At block 2201, a master battery pack detects a catastrophic failure of one or more of the battery cells of one of the battery packs that power the terminal device. For example, the battery voltage in the battery pack may drop below an acceptable minimum threshold; exceeding a maximum current; and/or the cell temperature is higher than the allowable range.

When the primary battery detects a catastrophic failure, then at block 2202 the primary battery determines whether additional batteries are needed. For example, when the terminal device only needs three battery packs with a given SoC level, the battery system may have activated four battery packs. If so, process 2200 disables the bad battery pack and continues to run at block 2203.

However, if additional battery packs are needed, at block 2204, the master battery pack determines whether an unused battery pack (which may be the master battery pack itself) in the battery system is available. If so, at block 2205, the master battery pack disables the bad battery pack (e.g., disables the discharge array) and enables the additional battery pack (e.g., enables the discharge array). If more than one additional battery pack is available, the master battery pack may select the additional battery pack having the largest SoC value in order to continue service for the largest possible time. However, when no additional battery packs are available and degraded operation of the terminal device is allowed, as determined at block 2206, the master battery pack disables the bad battery pack and sends a fault alert message to the terminal device regarding the degraded operation at block 2208. However, if the degraded operation is not acceptable for the terminal device, power is removed from the terminal device to shut down the terminal device at block 2207.

When a failure occurs at the slave battery packs, the slave battery packs may not send messages to the master battery pack in various failure modes. However, the master battery pack may determine that there is no longer communication from the slave battery pack and adjust the power level to the terminal device (de-rate).

Although the bad battery pack may be the slave battery pack, the master battery pack itself may be the bad battery pack. For example, one of the battery cells of the main battery pack may fail when its processing capacity is not compromised. If so, the primary battery may disable its own discharge array internally, attempt to enable the discharge array of the backup battery, and continue to operate as the primary battery.

For some embodiments, when a primary battery has failed, a new primary battery may be allocated even though the failed primary battery is still running. This approach ensures that a failed primary battery does not compromise the integrity of the overall processing of the other battery.

For some embodiments, when a primary battery has failed, a new primary battery may be allocated to allow continued performance degradation upon loss of communication with the failed primary battery.

Fig. 23A illustrates a message flow scenario for limp home mode operation according to an embodiment. In this scenario, when a catastrophic failure is detected at battery 2103a, a backup battery (battery 2104 a) is available.

At event 2151, in response to fault notification message 2161, master battery 2102a detects a catastrophic fault at battery 2103a. For example, the battery 2103a may provide battery status information indicating a low cell voltage. The status information may be in response to a query from the master battery pack 2102a, or may be automatically sent when a catastrophic event occurs. Thus, master battery 2102a enables backup battery 2104a and disables bad battery 2103a via messages 2163 and 2162, respectively.

Fig. 23B illustrates a message flow scenario for limp home mode operation, according to an embodiment. For this scenario, the battery backup is not available.

At event 2152, similar to the message scenario in fig. 23A, master battery pack 2102b detects a catastrophic failure at battery pack 2103b upon receiving a failure notification message 2164 from 2103 b. Because master battery 2102b determines that no backup battery is available, master battery 2102b disables battery 2103b via message 2165 and sends degradation message 2166 to terminal device 2101b, which terminal device 2101b is capable of operating in a degradation mode.

Referring to fig. 23A-23B, the fault notification messages 2161 and 2164 may be sent automatically from the battery packs causing the catastrophic failure, or may be sent in response to a request for battery status information from the master battery packs 2102a, 2102B. When autonomously transmitted, the battery pack may detect when a battery parameter (e.g., soH or battery voltage) drops to a predetermined threshold and then transmit a fault notification message to the master battery pack 2102a, 2102b. When sent in response to a status request, the master battery packs 2102a, 2102b may repeatedly (e.g., periodically) send the status request. The battery receives the status request and in response provides current battery status information. When one or more of the returned battery parameters falls below a predetermined threshold, the master battery pack 2102a, 2102b detects a catastrophic failure at the battery pack.

For some embodiments, the master battery packs 2102a, 2102b may receive periodic battery status information from other battery packs. When the master battery pack 2102a, 2102b detects a sudden drop in one of the battery parameters (e.g., battery voltage) (e.g., exceeding a predetermined difference relative to a previous value), the master battery pack 2102a, 2102b may determine that a catastrophic failure at the corresponding battery pack is predicted or imminent, and take preemptive action and/or generate a warning notification.

For some embodiments, battery cells 203 and 210 (shown in fig. 2A and 2B, respectively) may have a battery structure (e.g., a parallel structure) such that the battery pack may deactivate the failed battery cell while remaining active with the other battery cells. In this case, the battery pack may be operated in the degradation mode, and report to the master battery packs 2102a, 2102b that the battery pack is operating in the degradation mode.

Fig. 24 illustrates a battery pack system 2400 having a connector with a limp home mode signal output to an external device according to an embodiment disclosed herein. While banal technology for measuring voltage may be sufficient for lead acid batteries, with lithium ion batteries as illustrated throughout the disclosure herein, the system is much more complex and requires significant improvements and technology. Furthermore, some terminal devices traditionally powered by lead acid batteries or other conventional battery packs may not be equipped with a CAN communication bus communicatively coupled to the battery system. In this way, the terminal devices may have relied on other metrics and/or components to determine and trigger a limp home mode for the application of the terminal device. As a result, a battery pack system having a connector 219 is disclosed in fig. 24, the connector 219 being configured to output a signal (e.g., an analog signal) to an input line of a terminal device corresponding to a limp home mode.

One or more components in fig. 24 enable the run limp home mode signal to drive a controller or other hardware/software/firmware on the terminal device. An input connector is illustrated in fig. 24 that connects to a battery pack and provides power for the gateway Printed Circuit Board Assembly (PCBA) and also related data on the CAN communication bus from the battery pack. The gateway connector 219 is configured to communicatively couple with an interface to the terminal device to provide a limp home mode signal. The connector 219 may be connected to a switch 208, the switch 208 providing one of several possible signal levels to the connector 219: the ground signal (GND) is "PACK-", a5 volt signal that activates/triggers a limp home mode, a "pack+" signal that may be 5 volts or higher based on the requirements of the terminal device and its circuitry, and/or other signal levels and types. The microcontroller 213 provides switch control inputs to, among other things, the switch 208 as illustrated in fig. 24 to read messages from the battery pack through CAN communication, process the data, and execute logic to determine when to activate and deactivate the signals output by the connector. Although fig. 24 illustrates a switch and connector for limp home mode, the present disclosure contemplates other output signals.

Fig. 24 also illustrates a 5V buck regulator 218, which 5V buck regulator 218 may be used to convert the battery voltage and provide a regulated 5V voltage to connect to the switch 208 input signal when the switch 208 input signal is to be activated. Although fig. 24 illustrates a 5V regulated voltage, the present disclosure contemplates that the voltage input to switch 208 is one of several voltage values and/or types, depending on the requirements of the end device system. Further, a current limiter (e.g., a200 mA current limiter) may be included to limit the current on the signals input into the switch 208 so that the circuit is protected even if a user creates a short circuit to GND on these signals. Further, for the illustrative embodiment, a current limiter (e.g., a 1A current limiter) for the PACK+ signal lines may be included, wherein the battery voltage is connected to these signals when conditions for activating these signals are met. In such an example, the signal is protected from shorting to GND by the current limiter described above.

The intelligent battery pack in fig. 24 includes a Battery Management System (BMS) or battery management Integrated Circuit (IC) 204 that calculates a battery pack SoC using one or more algorithms. In some examples, computation of the SoC may be performed continuously, periodically, and/or upon request over one or more intervals. For example, the microcontroller 213 may request a SoC value from the battery management Integrated Circuit (IC) 204, which may then be provided to the microcontroller 213. The microcontroller may operate based on programmed logic, hardwired logic, and/or computer readable code stored in a memory device 202 coupled to the microcontroller 213. The code programs/controls the microcontroller 23 to switch between the plurality of signals available to it via the switch 208. For example, when a limp home mode is not required, the switch 208 may output a default of 0V. But when the condition for entering the limp home mode is satisfied, the switch 208 may be pulled up to the battery voltage or the regulated 5V voltage, depending on the application needs of the terminal device. Some illustrative conditions include: (i) SoC is below a threshold; (ii) One or more cells in a multi-battery system fail; and/or (iii) any other conditions necessary to cause the terminal device/application to operate with reduced performance so that the terminal device can safely end the current task.

In one example, when the SoC value provided by the battery management IC 204 is below a safety threshold, the microcontroller 213 may control the switch 208 to output a 5V or pack+ input signal instead of a default PACK-or 0V. In some examples, the security threshold may be adjusted/changed based on one or more criteria. For example, the value may be adjusted relative to a temperature measurement provided to the microcontroller 213 by the battery management IC 204. Because the remaining capacity decreases at low temperatures, the memory device 202 connected to the microcontroller 213 can store a look-up table (or equivalent data structure) that provides different safety thresholds corresponding to different temperature readings. In one example, the threshold may be 10% soc at 25 degrees celsius, 15% soc at 0 degrees celsius, and 20% soc at-15 degrees celsius. Although temperature is used as one example of the criteria in the above lookup table, the present disclosure is not limited thereto. Other criteria, such as the number of battery packs in a multi-battery system, may be different or additional criteria for storing look-up tables for different thresholds.

If the battery pack does not have a free pin that CAN be assigned to output a limp home signal, a gateway PCBA that communicates with the battery pack through an electronic communication protocol such as a Controller Area Network (CAN) bus CAN interface to the battery pack. Such a gateway (e.g., gateway PCBA) provides a "limp home" signal through connector 219, which connector 219 may be wired into the interface of the terminal device/application device. The gateway may monitor the communication messages from the battery pack and drive the output pin high when a limp home condition as defined by the microcontroller 213 and the memory device 202 is met. In some examples, connector 219 may interface with an existing electronic chip or electronic interface on the terminal device being powered to cause an interrupt to the terminal device. The interrupt may trigger the terminal device to enter a limp home mode.

Fig. 25A, 25B, and 25C (collectively, "fig. 25") are flowcharts of a connector outputting a limp home mode signal to an external device in accordance with one or more embodiments. Fig. 26A is similar to the message scenario in fig. 23B, where a primary battery 2102B detects a catastrophic failure at battery 2103B after receiving a failure notification message 2164. Because master battery 2102b determines that no backup battery is available, master battery 2102b disables battery 2103b via message 2165 and sends degradation message 2166 to terminal device 2101b, which terminal device 2101b is capable of operating in a degradation mode. Referring to fig. 23A and 23B, the fault notification messages 2161 and 2164 may be sent autonomously from the battery packs causing the catastrophic failure, or may be sent in response to a request for battery status information from the master battery packs 2102a, 2102B. When autonomously transmitted, the battery pack may detect when a battery parameter (e.g., SOH or SoC) falls to a predetermined threshold and then transmit a failure notification message to the master battery pack 2102a, 2102b. When sent in response to a status request, the master battery packs 2102a, 2102b may repeatedly (e.g., periodically) send the status request. The battery receives the status request and in response provides current battery status information. When one or more of the returned battery parameters falls below a predetermined threshold, the master battery pack 2102a, 2102b detects a catastrophic failure at the battery pack. For some embodiments, the master battery packs 2102a, 2102b may receive periodic battery status information from other battery packs. When the master battery pack 2102a, 2102b detects a sudden drop in one of the battery parameters (e.g., battery voltage, soC) (e.g., exceeding a predetermined difference relative to a previous value), the master battery pack 2102a, 2102b may determine that a catastrophic failure at the corresponding battery pack is predicted or imminent, and take a preemptive action and/or generate a warning notification. In such an instance, the look-up table stored in the memory device 202 may include a change over time of the SoC as a criterion for determining whether the microcontroller 213 triggers the connector 219 to output a limp home mode signal to the terminal device.

Figure 25A is a flow chart of a system involving logic resident in the gateway PCBA to determine when to activate a signal. As explained throughout this document, a battery system may support a "limp home mode" when a battery pack in the battery system experiences a catastrophic failure, for example, when its battery cells are characterized by a very low voltage output (e.g., a state of charge (SoC) reading of less than 10%, 5%, or other amount). The internal battery management system may diagnose the fault and may mitigate the fault in any of a number of ways, including but not limited to enabling the terminal device/device to "limp home" operation at least partially under power. For example, an initial value of a limp home signal to be deactivated may be set at block 2501. At block 2502, the battery system SoC, temperature, and/or battery number may be read from the master battery pack via CAN communication. A limp-home mode state of charge (SoC) threshold may be calculated at block 2503 from a lookup table using temperature and/or battery number as inputs. At blocks 2505 through 2509, a limp home mode signal is activated or deactivated based on the battery system SoC and SoC threshold.

Fig. 25B is a flow chart relating to a system including a power supply having a plurality of battery packs, similar to the system illustrated by the flow chart of fig. 22. After the master battery pack in the system detects a catastrophic failure of one or more battery cells of one battery pack that powers the terminal device, the master battery pack then determines whether additional battery packs are needed. For example, if the state of charge (SoC) level in a single battery of the system drops below an acceptable minimum threshold (or exceeds a maximum current and/or cell temperature is above an allowable range), the battery system may determine whether the terminal device only needs a certain amount of battery that is less than the amount currently active and operating at or above the acceptable minimum threshold. In one example, assuming the option illustrated in fig. 22 is not available, the master battery pack may continue to disable the bad battery pack (e.g., disable the discharge array) and generate a warning message over the communication bus (e.g., CAN communication bus) to inform the terminal device that the battery pack is operating in a degraded mode (e.g., limp home mode). In fig. 25B, the computing logic resides in the battery system, and the gateway PCBA reads/receives this signal from the master battery in the battery system and sets the hardware pins accordingly. This arrangement delegates computational logic to various components in the system, thereby better helping retrofit aspects of the present disclosure into legacy systems. In some examples illustrated herein, the computing logic may reside in a microcontroller 213 in the battery pack; while in other examples, the computing logic (as well as the switch 208 and connector 219) may reside in a gateway PCBA coupled to the intelligent battery pack via a CAN communication bus. Thus, even if the terminal device is not communicatively coupled to the CAN communication bus, the gateway PCBA (with the aforementioned components, such as the switch 208 and the connector 219) may activate a signal to cause the hardware pin corresponding to the limp home mode on the terminal device to be triggered. The triggering of the hardware pin causes the terminal device to react and respond to the generated alarm. For example, an initial value of a limp home signal to be deactivated may be set at block 2501. At block 2504, a lameness signal status may be read from the master battery pack through CAN communication. At blocks 2505 through 2509, a limp home mode signal is activated or deactivated based on whether the limp home signal is set.

Fig. 25C is a flow chart of a system involving hardware signals residing in the battery pack system and not using the gateway PCBA. Instead, the output signal from the battery pack may directly drive the limp home mode input signal on the terminal device. In some illustrative circuits including relays, the system 2400 output may be a pack+ voltage to drive the relay when 5V (or other preset voltage) may be insufficient. For example, an initial value of a limp home signal to be deactivated may be set at block 2501. A limp-home mode state of charge (SoC) threshold may be calculated at block 2503 from a lookup table using temperature and/or battery number as inputs. At blocks 2505 through 2509, a limp home mode signal is activated or deactivated based on the battery system SoC and SoC threshold.

Fig. 26A is similar to fig. 23A and 23B, where fig. 26A shows a message flow scenario where a connector outputs a limp home mode signal to an external device according to an embodiment. Further, fig. 26A shows illustrative communications inside a master battery 2102b in a multi-battery system, where a battery management system 2106 and a state of charge (SoC) measurement device 2107 interact to provide inputs to a microcontroller 213 controlling a switch 208. In some examples, BMS2105 may read/receive SoC values by sending a request for a value. In other examples, the reading/receiving may take the form of a push model, where the SoC measurement device may be registered with the BMS2105 and send a value when the incremental change in the measured value is above a certain threshold deviation. In some instances, instead of a push model, both components may automatically transmit values at periodic time intervals (e.g., a polling model). In another example, the pull model may be used to provide values only when the BMS2105 requests a value.

The message scenario in fig. 26B-26A, where master battery pack 2102B detects a catastrophic failure at battery pack 2103B after receiving failure notification message 2164. Because primary battery 2102b determines that no backup battery is available, primary battery 2102b disables battery 2103b via message 2165 and sends degradation message 2166 to external gateway PCBA2109, which interfaces with legacy terminal devices capable of operating in degradation mode. In some examples, external gateway PCBA2109 is capable of communicating with charger 2108 via message 2167. In some embodiments, the charger 2108 is a master charger in a stackable charging system, as depicted in fig. 30.

Fig. 27 shows an illustrative battery pack with signal connectors. The illustrative battery shows an example where two signals are integrated into the battery and are part of a signal connector. In such an instance, the limp home mode signal output by connector 219 would be read through a signal connector on the battery pack. In another example, the external gateway PCBA may be used to pull a limp home mode signal from the CAN communication bus in the battery pack and interface it with legacy terminal devices that do not have a CAN communication network bus.

Continuing with the previous example, fig. 28 shows an illustrative external gateway PCBA having a connector that can be used in the previous example to provide an interface to legacy terminal devices.

Fig. 29A and 29B (collectively, "fig. 29") are flowcharts for the connector to output a "full charge" notification signal. Although there are third party meters that measure the battery voltage across the positive and negative terminals of a battery (e.g., a lead acid battery) and then display an apparent SoC that depends on the battery voltage, this technique has several drawbacks, as explained below with respect to fig. 29B. In one example, a smart lithium ion battery system uses complex algorithms to measure the SoC inside the battery and provide SoC values over an electronic communication line (e.g., CAN communication bus) that CAN be read by an application/terminal device or charger to determine whether the battery is fully charged. However, some terminal devices/applications are not equipped to read messages over the CAN communication network bus-for example, conventional application devices using lead acid batteries typically do not have this capability.

Thus, fig. 29A shows a flow chart embodying a battery pack system in which the output hardware signal informing of the "fully charged" state resides in the gateway PCBA external to the battery pack and interfaces with the terminal device. Similar to the flowchart in fig. 25A, the full charge signal in fig. 29A is output using the microcontroller 213, the switch 208, and the connector 219. Microcontroller 213 can receive SoC readings from the battery management system of the master battery in the multi-battery system and control switch 208 accordingly. In a multi-stack parallel configuration, there is often an imbalance between the stacks, and the voltage measured from the positive and negative terminals of the system is an average of the stack terminal voltages—which can lead to inaccuracy in using a gauge to identify if the stack is fully charged. However, the system performing the steps of fig. 29A overcomes these drawbacks because the microcontroller 213 reads the SoC from the main battery pack, which combines socs from all battery packs. Meanwhile, in the multi-stack serial configuration, the voltage measured from the system terminals is the sum of the voltages of the stack terminals. One battery pack may be at a higher voltage than the other battery packs, which causes all battery packs to fully charge and stops charging all battery packs. For example, assume that two battery packs are connected in series, and the maximum charge voltage of the battery packs is 10V, so the maximum charge voltage of the system will be 20V. Due to the unbalance, it is assumed that the battery pack 1 voltage is 9V and the battery pack 2 voltage is 8V. When charging, the battery 1 voltage reaches 10V first, and the battery 2 voltage is 9V. When this occurs, the battery pack 1 terminates the charging, and then terminates the charging of the entire system. The system voltage is then 19V. The user may be confused: the charging has stopped but the meter only displays 90% (less than 100%), which is a value corresponding to a 19V system voltage. However, the system performing the steps of fig. 29A overcomes these drawbacks because the microcontroller 213 reads the SoC from the main battery, which is the higher of the socs reported by the two battery packs. In this case, when the battery pack 1 terminates charging, it will provide a value of 100%. For example, an initial value of a full charge signal to be deactivated may be set at block 2901. At block 2902, the battery system SoC may be read from the master battery pack through CAN communication. At blocks 2903-2907, the full charge signal is activated or deactivated based on whether the battery pack system SoC is at one hundred percent capacity.

Fig. 29B is an embodiment in which the hardware signals reside in the battery pack system and the gateway PCBA is not used. Although there are third party meters that measure the battery voltage at the battery terminals to determine the full charge state, they are inaccurate because the battery terminal voltage does not provide an accurate measurement of the SoC of the lithium ion battery, especially during charging or discharging. This is due, inter alia, to the impedance of the wires used to connect to the battery pack and the internal impedance of the power traces in the Battery Management System (BMS) Printed Circuit Board (PCB). During charging, the terminal voltage reads a value higher than the stack voltage, and during discharging, the terminal voltage reads a value lower than the stack voltage. Thus, if only the voltmeter is used to ascertain whether the battery pack is fully charged, the system will identify a fully charged battery pack before the battery pack is actually fully charged. Therefore, even when the battery pack is not fully charged, the terminal device can disconnect the charger. This may result in a low discharge capacity of the battery pack. The systems and processes disclosed herein overcome this technical disadvantage. The system 2400 disclosed herein relies on a SoC calculated by a BMS that uses complex algorithms to calculate. Furthermore, the outputted full charge notification signal provides a better, more accurate indication of the full charge state of the battery system attached to the powered terminal device. For example, an initial value of a full charge signal to be deactivated may be set at block 2901. At blocks 2903-2907, the full charge signal is activated or deactivated based on whether the battery pack system SoC is at one hundred percent capacity.

The intelligent battery pack has a Battery Management System (BMS) that calculates a battery pack state of charge (SoC). In some embodiments, a Battery Management System (BMS) is disclosed that enables a smart lithium ion battery pack to notify one or more application devices lacking electronic communication means that require the application device to enter a limp home mode when certain conditions are met. These conditions include, but are not limited to: a state of charge (SoC) below a safety threshold, one or more battery packs in a multi-battery system failing, and/or any other condition requiring an application device to operate in a low power mode. In some embodiments, the SoC is continuously calculated using one or more complex algorithms. When the condition for entering the limp home mode is met, the battery pack may add a new analog signal, "limp home" thereto, which defaults to 0V and is pulled up to the battery pack voltage or regulated 5V voltage as needed by the terminal device/application. These conditions may include: (1) The SoC is below a safety threshold, where the threshold may vary with respect to temperature, as the remaining capacity decreases at low temperatures. For example, the threshold may be 10% soc at 25 degrees celsius, 15% soc at 0 degrees celsius, and 20% soc at-15 degrees celsius; (2) One or more battery packs in the multi-battery system fail; and/or (3) any other conditions necessary to cause the application device to run at reduced performance so that the user can safely end the current task.

If the battery pack does not have an idle/available/unused pin that CAN be assigned for a limp home signal, a gateway Printed Circuit Board Assembly (PCBA) that communicates with the battery pack through an electronic communication protocol such as a Controller Area Network (CAN) CAN interface to the battery pack. The gateway PCBA may provide a "limp home" signal through a connector that may be wired to the terminal device/application. The gateway PCBA may monitor communication messages from the battery pack and drive the pin high when a limp home condition is met. In some examples, the reference voltage for the "limp home" signal is PACK. Application devices that use conventional lead acid batteries and/or lead acid batteries without electronic communication capabilities are the primary focus of the features disclosed herein. In particular, any intelligent battery pack that internally calculates the SoC is the primary focus of the features disclosed herein. By adding a limp home signal, these devices can be upgraded to a lithium ion battery and monitor for a limp home signal.

Many illustrative embodiments are listed below in accordance with one or more aspects disclosed herein. Although many of the embodiments listed below are described as being dependent on other embodiments, the dependencies are not limited thereto. For example, embodiment 5 (below) is explicitly described as combining features of embodiment 1 (below), however, the present disclosure is not limited thereto. For example, embodiment 5 may depend on any one or more of the foregoing embodiments (i.e., embodiment 1, embodiment 2, embodiment 3, and/or embodiment 4). Furthermore, the present disclosure contemplates that any one or more of embodiments 2 through 12 may be incorporated into embodiment 1. Likewise, any of embodiments 1, 14, 17, 22 may be combined with one or more of the features described in embodiments 2 to 13, 15 to 16, 18 to 21, and/or 23 to 26. Further, as such, any of embodiments 27, 39, 43 may be combined with one or more of the features described in embodiments 28 to 38, 40 to 42, 44 to 46. Further, as such, any of embodiments 47, 59, 64 may be combined with one or more of the features described in embodiments 48 to 58, 60 to 63, 65 to 69. Further, as such, any of embodiments 70, 87, 92 may be combined with one or more of the features described in embodiments 71 to 86, 88 to 91, 93 to 94. Further, as such, any of embodiments 95, 105, 109 may be combined with one or more of the features described in embodiments 96-104, 106-108, 110-114. In addition, the present disclosure contemplates that any one or more of the features of embodiments 1, 14, 17, 22, 27, 39, 43, 47, 59, 64, 70, 87, 92, 95, 105, and 109 can be combined. Furthermore, the present disclosure contemplates that any one or more of the features of embodiments 1 through 114 may be combined.

Embodiment 1. A first battery pack configured for installation in a battery system for powering a terminal device, wherein all installed battery packs installed in the battery system have substantially identical electrical and electronic components, the first battery pack comprising:

A communication interface circuit configured to interface to a communication channel;

a power bus interface circuit configured to interface with a power bus and provide power to the terminal device;

a controller comprising at least one processor; and

A memory storing controller instructions that, when executed by the at least one processor, cause the controller to:

acquiring a configuration list of battery packs installed in the battery system, wherein a first entry corresponds to the first battery pack;

Configuring the first battery pack to be used as a master battery pack for the battery system when the first entry of the configuration list has a highest priority location in the configuration list, wherein the highest priority location indicates that the first battery pack was installed before any other active battery packs in the battery system;

Revising the configuration list when a second battery pack is installed or removed from the battery system; and

The configuration list is repeatedly broadcast to all of the installed battery packs over the communication channel via the communication interface circuit.

Embodiment 2. The first battery pack of embodiment 1, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

Detecting an insertion of a third battery pack when the third battery pack is added to the battery system; and

A third entry is created in the configuration list for the third battery pack, wherein the third entry is at a bottom position of the configuration list.

Embodiment 3. The first battery pack of embodiment 2, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

detecting removal of the second battery pack when the second battery pack is removed from the battery system; and

And deleting a second entry of the second battery pack in the configuration list.

Embodiment 4. The first battery pack of embodiment 3, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

and advancing a list position of the third entry of the third battery pack in the configuration list.

Embodiment 5. The first battery pack of embodiment 1, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

The first battery pack is configured to function as a first slave battery pack when the first entry of the first battery pack is not at the highest priority location in the configuration list.

Embodiment 6. The first battery pack of embodiment 5, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

the first battery pack is configured to function as the master battery pack when another battery pack is removed from the battery system and the first entry moves to the highest priority location of the configuration list.

Embodiment 7. The first battery pack of embodiment 1, wherein the communication channel comprises a Controller Area Network (CAN) bus, and wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

An Identification (ID) of the first battery pack is obtained using an SAE J1939 address declaration procedure, wherein the ID is included in the first entry.

Embodiment 8. The first battery pack of embodiment 5, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

When the first battery pack is used as the first slave battery pack:

receiving a first request from the master battery pack; and

Responsive to receiving the first request, the first request from the primary battery pack is responded to.

Embodiment 9. The first battery pack of embodiment 1, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

when the first battery pack is used as the main battery pack:

transmitting a second request to a second slave battery pack; and

Responsive to the transmitting, a response message is received from the second slave battery pack.

Embodiment 10. The first battery pack of embodiment 1, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

Transmitting a join request over the communication channel when the first battery pack is removed from and reinserted into the battery system; and

The configuration list is received with a fourth entry at a bottom position in the configuration list, wherein the fourth entry is associated with the first battery pack.

Embodiment 11. The first battery pack of embodiment 1, the first battery pack comprising a non-volatile memory, and wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

Storing battery pack information in the non-volatile memory; and

The battery pack information is retained when the first battery pack is removed from and reinserted into the battery system.

Embodiment 12. The first battery pack of embodiment 2, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

when the first battery pack is used as the main battery pack:

transmitting a repeated broadcast message to all of the installed battery packs over the communication channel via the communication interface circuit; and

And removing the third entry from the configuration list when a repeated broadcast message is not received from the third battery.

Embodiment 13. The first battery pack of embodiment 12, wherein the repeated broadcast message is sent periodically, and wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

The third entry is removed from the configuration list when a timer set to a predetermined time expires without receiving the repeated broadcast message.

Embodiment 14. A battery system configured to power a terminal device and including a plurality of battery packs, the battery system comprising:

a first battery pack, the first battery pack comprising:

a first communication interface circuit configured to interface to a Controller Area Network (CAN) bus;

A first controller comprising at least one processor; and

A first memory storing controller instructions that, when executed by the at least one processor, cause the first controller to:

acquiring a configuration list of battery packs installed in the battery system, wherein a first entry corresponds to the first battery pack;

Configuring the first battery pack to be used as a master battery pack for the battery system when the first entry of the configuration list has a highest priority location in the configuration list, wherein the highest priority location indicates that the first battery pack was installed before any other active battery packs in the battery system;

When the first battery pack is used as the main battery pack, revising the configuration list when a third battery pack is installed or removed from the battery system; and

Repeatedly broadcasting the configuration list to all installed battery packs through the CAN bus via the first communication interface circuit; and

And a second battery pack having the same electrical and electronic components as the first battery pack.

Embodiment 15. The battery system of embodiment 14, wherein the second battery pack includes:

a second communication interface circuit configured to interface to the Controller Area Network (CAN) bus;

a second controller comprising one or more processors; and

A second memory storing controller instructions that, when executed by the one or more processors, cause the second controller to:

Acquiring the configuration list of the installed battery packs in the battery system, wherein a second entry corresponds to the second battery pack;

configuring the second battery pack to function as the primary battery pack for the battery system when the second entry of the configuration list has a highest priority location in the configuration list, wherein the highest priority location indicates that the second battery pack was installed before the any other active battery packs in the battery system;

Revising the configuration list when the third battery pack is installed or removed from the battery system; and

The configuration list is repeatedly broadcast to all of the installed battery packs over the CAN bus via the second communication interface circuit.

Embodiment 16. The battery system of embodiment 15, wherein the first controller instructions, when executed by the one or more processors, further cause the first controller to:

The first battery pack is configured to function as the master battery pack when the second battery pack was previously used as the master battery pack when the first entry is in a second position from the highest priority position in the configuration list.

Embodiment 17. A method of powering a terminal device by a battery system, the method comprising:

acquiring a configuration list of battery packs installed in the battery system, wherein a first entry corresponds to a first battery pack;

Configuring the first battery pack to be used as a master battery pack for the battery system when the first entry of the configuration list has a highest priority location in the configuration list, wherein the highest priority location indicates that the first battery pack was installed before any other active battery packs in the battery system;

Revising the configuration list when a second battery pack is installed or removed from the battery system; and

The configuration list is repeatedly broadcast over a communication channel to all installed battery packs via the communication interface circuit.

Embodiment 18. The method of embodiment 17, further comprising:

detecting an insertion of a third battery pack when the third battery pack is added to the battery system;

Creating a third entry in the configuration list for the third battery pack, wherein the third entry is at a bottom position of the configuration list; and

In response to creation, broadcasting the configuration list to the all installed battery packs configured in the battery system via the communication channel.

Embodiment 19. The method of embodiment 18, further comprising:

Detecting removal of the second battery pack when the second battery pack is removed from the battery system; and

And deleting a second entry of the second battery pack in the configuration list.

Embodiment 20. The method of embodiment 17, further comprising:

The first battery pack is configured to function as a slave battery pack when the first entry of the first battery pack is not at the highest priority location in the configuration list.

Embodiment 21. The method of embodiment 20, further comprising:

the first battery pack is configured to function as the master battery pack when another battery pack is removed from the battery system and the first entry moves to the highest priority location of the configuration list.

Embodiment 22. A battery system configured to power a terminal device and including a plurality of battery packs, the battery system comprising:

A power bus coupled to the terminal device to provide power to the terminal device;

A communication channel coupled to the plurality of battery packs;

a first battery pack, the first battery pack comprising:

a first communication interface circuit configured to interface to the communication channel;

a first discharge array;

A first processor; and

A first memory storing computer-executable instructions that, when executed by the first processor, cause the first battery pack to:

disabling the first discharge array to prevent discharge from the first battery pack onto the power bus;

acquiring a first open-circuit voltage measurement value of the first battery pack; and

Sharing the first open circuit voltage measurement with the plurality of battery packs via the communication channel;

Maintaining a first copy of a configuration list based on the first open circuit voltage measurement and a shared open circuit voltage measurement from the plurality of battery packs; and

Enabling the first discharge array to allow discharge onto the power bus; and

A second battery pack, the second battery pack comprising:

a second communication interface circuit configured to interface to the communication channel;

a second discharge array electrically connected to the power bus of the battery system;

a second processor; and

A second memory storing computer executable instructions that, when executed by the second processor, cause the second battery pack to:

disabling the second discharge array to prevent discharge from the second battery pack onto the power bus;

Acquiring a second open circuit voltage measurement of the second battery pack; and

Sharing the second open circuit voltage measurement with the plurality of battery packs via the communication channel;

Maintaining a second copy of the configuration list based on the second open circuit voltage measurement and the shared open circuit voltage measurement from the plurality of battery packs, wherein the configuration list is ordered based on reduced open circuit voltage measurements, and wherein a top member of the configuration list is designated as a master battery pack of the battery system; and

The second discharge array is enabled to allow discharge onto the power bus.

Embodiment 23. The battery system according to embodiment 22, comprising:

A third battery pack, wherein the third battery pack is installed in the battery system when the first battery pack and the second battery pack are discharged onto the power bus, the third battery pack comprising:

a third communication interface circuit configured to interface to the communication channel;

a third discharge array;

A third processor; and

A third memory storing computer executable instructions that, when executed by the third processor, cause the third battery pack to:

Disabling the third discharge array to prevent discharge from the third battery pack onto the power bus;

Acquiring a third open-circuit voltage measurement value of the third battery pack; and

The third open circuit voltage measurement is shared with the plurality of battery packs via the communication channel.

Embodiment 24. The battery system of embodiment 23, wherein the third memory stores computer-executable instructions that, when executed by the third processor, cause the third battery pack to:

a third copy of the configuration list is updated based on the third open circuit voltage measurement and the shared open circuit voltage measurement from the plurality of battery packs.

Embodiment 25. The battery system of embodiment 24, wherein the updating occurs after the first battery pack and the second battery pack are disconnected from the battery system.

Embodiment 26. The battery system of embodiment 24, wherein the updating occurs when the first battery pack and the second battery pack discharge onto the power bus.

Embodiment 27. A method of powering a terminal device by a battery system, the battery system comprising a plurality of previously installed battery packs, wherein the plurality of previously installed battery packs comprises a master battery pack, the method comprising:

Inserting an additional battery pack into the battery system, establishing a first connection to a power bus and a second connection to a communication bus;

interacting with the main battery pack through the additional battery pack; and

In response to the interaction, an inrush current from the additional battery pack to one of the plurality of previously installed battery packs is prevented.

Embodiment 28. The method of embodiment 27 wherein the preventing comprises:

A first disable message is received by the additional battery pack from the main battery pack via the communication bus, wherein the first disable message instructs the additional battery pack to disable charging and discharging through the power bus.

Embodiment 29. The method of embodiment 27, further comprising:

An insertion indication is provided by the additional battery pack via the communication bus in response to the insertion, wherein the insertion indication includes an Identification (ID) of the additional battery pack.

Embodiment 30. The method of embodiment 29, further comprising:

In response to providing, a configuration message is received, wherein the configuration message includes a configuration list indicating a configuration of a battery system, wherein an entry in the configuration list for the additional battery pack is located at a bottom position of the configuration list, and wherein the additional battery pack is used as a slave battery pack in the battery system.

Embodiment 31. The method of embodiment 30, further comprising:

Obtaining, by the additional battery pack, first battery state information regarding a battery cell located at the additional battery pack, wherein the first battery state information includes a first state of charge (SoC) value of the battery cell;

receiving, by the additional battery pack, a first status request for the first battery status information from the main battery pack over the communication bus; and

In response to receiving the first status request, the first SoC value is sent to the master battery pack over the communication bus.

Embodiment 32. The method of embodiment 31, further comprising:

receiving the first SoC value from the additional battery pack;

determining, by the master battery pack, whether to initiate a charge balance including the additional battery pack based on the first SoC value; and

In response to determining, an enable message is sent by the master battery pack to the additional battery pack to configure the additional battery pack and the power bus.

Embodiment 33. The method of embodiment 32, further comprising:

Receiving, by the additional battery pack, the enabling message from the master battery pack via the communication bus; and

The additional battery pack is configured to interact with the power bus in accordance with the enabling message.

Embodiment 34. The method of embodiment 32 wherein the determining whether to initiate charge balancing comprises:

Transmitting, by the master battery pack, the enable message instructing the additional battery pack to enable discharge of the battery cells onto the power bus when the first SoC value is a high SoC value relative to the plurality of previously installed battery packs; and

The enabling message is sent by the master battery pack when the first SoC value is a low SoC value relative to the plurality of previously installed battery packs, the enabling message instructing the additional battery pack to enable charging of the battery cells from the power bus.

Embodiment 35. The method of embodiment 34 wherein the determining whether to initiate charge balancing further comprises:

When the first SoC value is equal to the low SoC value and a difference between the high SoC value and the low SoC value is greater than a predetermined amount, the enable message is sent, the enable message instructing the additional battery pack to enable the charging of the battery cells from the power bus through a converter located at the additional battery pack.

Embodiment 36. The method of embodiment 34, further comprising:

After receiving the enabling message from the main battery by the additional battery, obtaining a second SoC value of the battery cell;

receiving, by the additional battery pack, a second status request for second battery status information from the main battery pack over the communication bus; and

In response to receiving the second status request, the second SoC value is sent to the master battery pack over the communication bus.

Embodiment 37. The method of embodiment 36, further comprising:

Receiving the second SoC value from the additional battery pack;

Transmitting, by the main battery, a second disable message when the first SoC value is equal to the high SoC value and the second SoC value is below a first threshold, the second disable message instructing the additional battery to terminate discharge of the battery cell onto the power bus; and

When the first SoC value is equal to the low SoC value and the second SoC value is greater than a second threshold, the second disable message is sent by the master battery pack, the second disable message instructing the additional battery pack to terminate charging of the battery cells from the power bus.

Embodiment 38. The method of embodiment 27 wherein the communication bus comprises a Controller Area Network (CAN) bus.

Embodiment 39. A first battery pack configured to be mounted in a battery system to power a terminal device, wherein all mounted battery packs mounted in the battery system have identical electrical and electronic components, the first battery pack comprising:

A communication interface circuit configured to interface to a communication channel;

a power bus interface circuit configured to interface with a power bus and provide power to the terminal device;

a controller comprising at least one processor; and

A memory storing controller instructions that, when executed by the at least one processor, cause the controller to:

an insertion indication is generated via the communication channel when the first battery pack is inserted into the battery system, wherein the insertion indication includes an Identification (ID) of the first battery pack.

In response to generating the insertion indication, a message is received from a main battery pack detention of the battery system over the communication channel via the communication interface circuit; and

In response to receiving the disable message, charging and discharging through the power bus is disabled.

Embodiment 40. The first battery pack of embodiment 39, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

In response to generating the insertion indication, a configuration message is received, wherein the configuration message includes a configuration list indicating a battery system configuration, wherein an entry in the configuration list for the first battery pack is located at a bottom position of the configuration list, and wherein the first battery pack is used as a slave battery pack in the battery system.

Embodiment 41. The first battery pack of embodiment 40, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

Acquiring battery state information about a battery cell located at the first battery pack, wherein the battery state information includes a state of charge (SoC) value of the battery cell;

Receiving a status request for the battery status information from the main battery pack over the communication channel; and

In response to receiving the status request, the SoC value is transmitted to the master battery pack over the communication channel.

Embodiment 42. The first battery pack of embodiment 41, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

receiving an enable message from the master battery pack via the communication channel in response to transmitting the SoC value; and

And configuring the power bus interface circuit to interact with the power bus according to the enabling message.

Embodiment 43. A battery system configured to power a terminal device and including a plurality of battery packs, the battery system comprising:

a first battery pack, the first battery pack comprising:

a power bus interface circuit configured to interface with a power bus and provide power to the terminal device;

a first communication interface circuit configured to interface to a Controller Area Network (CAN) bus;

A first controller comprising at least one processor; and

A first memory storing controller instructions that, when executed by the at least one processor, cause the first controller to:

providing an insertion indication via the CAN bus when the first battery pack is inserted into the battery system, wherein the insertion indication includes an Identification (ID) of the first battery pack;

In response to providing, receiving a first disable message from a main battery pack of the battery system over the CAN bus via the first communication interface circuit; and

Disabling charging and discharging through the power bus in response to receiving; and

A second battery pack that serves as the main battery pack of the battery system.

Embodiment 44 the battery system of embodiment 43, wherein the first memory stores controller instructions that, when executed by the at least one processor, cause the first controller to:

Acquiring battery state information about a battery cell located at the first battery pack, wherein the battery state information includes a state of charge (SoC) value of the battery cell;

receiving a status request for the battery status information from the main battery pack through the CAN bus; and

In response to receiving the status request, the SoC value is sent to the master battery pack over the CAN bus.

Embodiment 45 the battery system of embodiment 44, wherein the second battery pack includes:

a second communication interface circuit configured to interface to the CAN bus;

a second controller comprising one or more processors; and

A second memory storing controller instructions that, when executed by the one or more processors, cause the second controller to:

Receiving the SoC value from the first battery pack;

Determining, by the master battery pack, whether to initiate a charge balance including the first battery pack based on the SoC value; and

An enable message is sent by the primary battery to the first battery pack to configure the first battery pack and the power bus in response to determining whether to initiate charge balancing.

Embodiment 46. The battery system of embodiment 45, wherein the second memory stores controller instructions that, when executed by the one or more processors, further cause the second controller to:

Transmitting, by the master battery pack, the enable message when the SoC value is a high SoC value relative to a plurality of previously installed battery packs, the enable message instructing the first battery pack to enable discharge of the battery cells onto the power bus; and

The enabling message is sent by the master battery pack when the SoC value is a low SoC value relative to the plurality of previously installed battery packs, the enabling message instructing the first battery pack to enable charging of the battery cells from the power bus.

Embodiment 47. A first battery pack configured for installation in a battery system to power a terminal device, wherein all installed battery packs installed in the battery system have identical electrical and electronic components, the first battery pack comprising:

one or more battery cells;

A communication interface circuit configured to interface to a communication channel;

a power bus interface circuit configured to interface with a power bus and provide power to the terminal device;

a controller comprising at least one processor; and

A memory storing controller instructions that, when executed by the at least one processor, cause the controller to:

Determining the first battery pack as a main battery pack of the battery system;

Determining whether a first backup battery pack is available when the first battery pack receives a first failure notification message from a second battery pack over the communication channel via the communication interface circuit and when additional battery packs are needed, wherein the first failure notification message indicates a first catastrophic failure at the second battery pack;

When the first backup battery is the only backup battery, and when the additional battery is needed, sending a first enabling message to the first backup battery through the communication channel, wherein the first enabling message instructs the first backup battery to discharge onto the power bus; and

When the first battery receives the first failure notification message from the second battery, a first disable message is sent to the second battery over the communication channel, wherein the first disable message instructs the second battery to terminate discharging onto the power bus.

Embodiment 48. The first battery pack of embodiment 47, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

When the first battery pack is the main battery pack of the battery system:

and when no standby battery pack is available, sending a degradation alarm message to the terminal device.

Embodiment 49 the first battery pack of embodiment 48, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

When the first battery pack is the main battery pack of the battery system:

And when the degradation operation is not acceptable by the terminal equipment, starting the shutdown of the battery system.

Embodiment 50. The first battery pack of embodiment 49, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

When the first battery pack is the main battery pack of the battery system:

commanding discharge of all battery packs of the battery system onto the power bus.

Embodiment 51. The first battery pack of embodiment 47, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

When the first battery pack is the main battery pack of the battery system:

Selecting a highest SoC battery backup from a plurality of battery backup packs when the plurality of battery backup packs are available, wherein the highest SoC battery backup pack is characterized by a highest state of charge (SoC) value for all of the plurality of battery backup packs; and

And sending a second enabling message to the highest SoC battery backup pack, wherein the second enabling message instructs the highest SoC battery backup pack to discharge onto the power bus.

Embodiment 52. The first battery pack of embodiment 47 wherein the communication channel comprises a Controller Area Network (CAN) bus.

Embodiment 53. The first battery pack of embodiment 47, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

When the first battery pack is the main battery pack of the battery system:

monitoring the one or more battery cells;

Determining, based on the monitoring, whether a second catastrophic failure has occurred;

determining whether the first backup battery pack is available when the second catastrophic failure has occurred;

Sending the first enabling message to the first backup battery when the first battery is available, wherein the first enabling message instructs the first backup battery to discharge onto the power bus; and

Self-disabling is disabled from discharging onto the power bus.

Embodiment 54. The first battery pack of embodiment 47, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

When the first battery pack is a slave battery pack of the battery system:

monitoring the one or more battery cells;

Determining, based on the monitoring, whether a third catastrophic failure has occurred; and

When the third catastrophic failure has occurred, a second failure notification message is sent to the primary battery pack of the battery system.

Embodiment 55. The first battery pack of embodiment 54, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

receiving a second disabling message from the primary battery pack in response to the transmitting; and

In response to receiving, terminating discharge onto the power bus.

Embodiment 56. The first battery pack of embodiment 47, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

Internally terminating discharge onto the power bus when the first battery pack detects an internal catastrophic failure;

Enabling one of the at least one battery backup packs when the at least one battery backup is available;

and when no standby battery pack is available, sending a degradation alarm message to the terminal device. And

Operation of the main battery pack as the battery system is continued.

Embodiment 57. The first battery pack of embodiment 47, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

Internally terminating discharge onto the power bus when the first battery pack detects an internal catastrophic failure; and

And reassigning one of the slave battery packs to a new master battery pack.

Embodiment 58 the first battery pack of embodiment 47, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

Attempting to disable the second battery pack from discharging onto the power bus when the first battery pack fails to receive any messages from the second battery pack over the communication channel; and

Adjusting the power level of the power bus to the terminal device.

Embodiment 59. A method of powering a terminal device by a battery system, the method comprising:

determining whether a first backup battery pack is available when a master battery pack receives a fault notification message from a slave battery pack over a communication channel, and when additional battery packs are needed, wherein the fault notification message indicates a catastrophic fault at the slave battery pack;

Transmitting, by the master battery pack, an enabling message to the first backup battery pack when the first backup battery pack is the only backup battery pack and when the additional battery pack is needed, wherein the enabling message instructs the first backup battery pack to discharge onto a power bus; and

And when the master battery pack receives the fault notification message from the slave battery pack, sending a disable message to the slave battery pack by the master battery pack, wherein the disable message instructs the slave battery pack to terminate discharging onto the power bus.

Embodiment 60. The method of embodiment 59, comprising:

And when the degradation operation is not acceptable by the terminal equipment, starting the shutdown of the battery system.

Embodiment 61. The method of embodiment 59, comprising:

Selecting a highest SoC battery backup from a plurality of battery backup packs when the plurality of battery backup packs are available, wherein the highest SoC battery backup pack is characterized by a highest state of charge (SoC) value for all of the plurality of battery backup packs; and

The enabling message is sent to the highest SoC battery backup pack, wherein the enabling message instructs the highest SoC battery backup pack to discharge onto the power bus.

Embodiment 62. The method of embodiment 59, comprising:

Monitoring one or more battery cells by the slave battery pack;

Determining, based on the monitoring, whether the catastrophic failure has occurred; and

When the catastrophic failure has occurred, the failure notification message is sent to the primary battery pack of the battery system.

Embodiment 63. The method of embodiment 62, comprising:

Receiving, by the slave battery pack, the disable message from the master battery pack in response to the transmitting; and

Responsive to receiving the disable message, terminating discharging onto the power bus.

Embodiment 64. A battery system configured to power a terminal device and including a plurality of battery packs, the battery system comprising:

a slave battery pack; and

A main battery pack, the main battery pack comprising:

a first communication interface circuit configured to interface to a Controller Area Network (CAN) bus;

A first controller comprising at least one processor; and

A first memory storing controller instructions that, when executed by the at least one processor, cause the first controller to:

determining whether a first backup battery pack is available when the master battery pack receives a fault notification message from the slave battery pack over the CAN bus via the first communication interface circuit and when additional battery packs are needed, wherein the fault notification message indicates a catastrophic fault at the slave battery pack;

When the first backup battery is the only backup battery, and when the additional battery is needed, sending an enabling message to the first backup battery, wherein the enabling message instructs the first backup battery to discharge onto a power bus; and

When the master battery pack receives the fault notification message from the slave battery pack, a disable message is sent to the slave battery pack, wherein the disable message instructs the slave battery pack to terminate discharging onto the power bus.

Embodiment 65. The battery system of embodiment 64, wherein the first memory stores controller instructions that, when executed by the at least one processor, cause the first controller to:

And when the degradation operation is not acceptable by the terminal equipment, starting the shutdown of the battery system.

Embodiment 66. The battery system of embodiment 65, wherein the first memory stores controller instructions that, when executed by the at least one processor, cause the first controller to:

commanding discharge of all battery packs of the battery system onto the power bus.

Embodiment 67. The battery system of embodiment 64, wherein the first memory stores controller instructions that, when executed by the at least one processor, cause the first controller to:

Selecting a highest SoC battery backup from a plurality of battery backup packs when the plurality of battery backup packs are available, wherein the highest SoC battery backup pack is characterized by a highest state of charge (SoC) value for all of the plurality of battery backup packs; and

The enabling message is sent to the highest SoC battery backup pack, wherein the enabling message instructs the highest SoC battery backup pack to discharge onto the power bus.

Embodiment 68. The battery system of embodiment 64, wherein the slave battery pack comprises:

a second communication interface circuit configured to interface to a Controller Area Network (CAN) bus;

A second controller comprising one or more processors;

one or more battery cells; and

A second memory storing controller instructions that, when executed by the one or more processors, cause the first controller to:

monitoring the one or more battery cells;

Determining, based on the monitoring, whether the catastrophic failure has occurred; and

When the catastrophic failure has occurred, the failure notification message is sent to the primary battery pack of the battery system.

Embodiment 69 the battery system of embodiment 68, wherein the second memory stores controller instructions that, when executed by the one or more processors, cause the second controller to:

Receiving the disabling message from the primary battery pack in response to sending the failure notification message; and

Responsive to receiving the disable message, terminating discharging onto the power bus.

Embodiment 70. A method of powering a terminal device by a battery system, the battery system comprising a plurality of battery packs, the method comprising:

Collecting, by a master battery pack of the battery system, battery state information from the plurality of battery packs, wherein the plurality of battery packs includes the master battery pack and all slave battery packs, and wherein the battery state information includes state of charge (SoC) data;

determining, by the master battery pack, whether a first subset of the plurality of battery packs require charge balancing based on the battery state information;

Selecting, by the master battery pack, a first balance type from a plurality of balance types suitable for the first subset of the plurality of battery packs; and

A first balancing type selected by the master battery pack via a power bus application until a desired SoC value is obtained for the first subset of the plurality of battery packs.

Embodiment 71. The method of embodiment 70 wherein the plurality of balancing types includes a converter balancing technique, a direct balancing technique, and an interleaved balancing technique.

Embodiment 72. The method of embodiment 71, comprising:

Identifying, by the master battery pack, a first battery pack having a high SoC value from the collected battery state information; and

The high SoC value is compared by the master battery pack to SoC values of all remaining battery packs.

Embodiment 73. The method of embodiment 72, comprising:

in response to the comparison, the converter balancing technique is initiated by the master battery pack for the first battery pack and the second battery pack when a first SoC difference between the first battery pack and the second battery pack is greater than a first predetermined amount.

Embodiment 74. The method of embodiment 73, comprising:

Transmitting, by the master battery pack, a first enabling message to the first battery pack over a communication channel, wherein the first enabling message instructs the first battery pack to discharge over the power bus; and

A second enable message is sent by the master battery pack to the second battery pack over the communication channel, wherein the second enable message instructs the second battery pack to enable its converter and charge from the power bus.

Embodiment 75. The method of embodiment 73, comprising:

in response to the comparison, the converter balancing technique is initiated by the master battery pack for the first battery pack, the second battery pack, and the third battery pack when a second SoC difference value between the first battery pack and the third battery pack is greater than a first predetermined amount.

Embodiment 76. The method of embodiment 75 wherein one of the first battery pack, the second battery pack, and the third battery pack is used as the master battery pack for the battery system.

Embodiment 77. The method of embodiment 72, comprising:

in response to the comparison, the direct balancing technique is initiated by the master battery pack for the first battery pack and the fourth battery pack when a third SoC difference value between the first battery pack and the fourth battery pack is less than a second predetermined amount.

Embodiment 78. The method of embodiment 77, comprising:

Transmitting, by the master battery pack, a third enabling message to the first battery pack over a communication channel, wherein the third enabling message instructs the first battery pack to discharge over the power bus; and

And sending, by the master battery pack, a fourth enabling message to the fourth battery pack over the communication channel, wherein the fourth enabling message instructs the fourth battery pack to charge from the power bus.

Embodiment 79. The method of embodiment 77 wherein one of the first battery pack and the fourth battery pack is used as the master battery pack.

Embodiment 80. The method of embodiment 72, comprising:

In response to the comparison, the cross balancing technique is initiated for the first battery, the fifth battery, and the sixth battery when a fourth SoC difference between the first battery and a fifth battery is less than a third predetermined amount, a fifth SoC difference between the first battery and a sixth battery is greater than a fourth predetermined amount, and a sixth SoC difference between the first battery and a seventh battery is greater than the fourth predetermined amount.

Embodiment 81. The method of embodiment 80, comprising:

transmitting, by the master battery pack, a fifth enabling message to the first battery pack over a communication channel, wherein the fifth enabling message instructs the first battery pack to discharge over the power bus;

Transmitting, by the master battery pack, a sixth enabling message to the fifth battery pack over the communication channel, wherein the sixth enabling message instructs the fifth battery pack to charge from the power bus, wherein the direct balancing technique is applied to the first battery pack and the fifth battery pack; and

A seventh enable message is sent by the master battery pack to the sixth battery pack over the communication channel, wherein the seventh enable message instructs the sixth battery pack to enable its converter and charge from the power bus, wherein the converter balancing technique is applied to the first battery pack and the sixth battery pack.

Embodiment 82. The method of embodiment 81, comprising:

acquiring current SoC values of the fifth battery pack and the sixth battery pack; and

In response to the acquiring, when an eighth difference between the first present SoC value of the fifth battery pack and the second current SoC value of the sixth battery pack is greater than a fifth predetermined value, the direct balancing technique is switched from the first battery pack and the sixth battery pack to the first battery pack and the seventh battery pack.

Embodiment 83. The method of embodiment 82, comprising:

Transmitting, by the master battery pack, an eighth enable message to the fifth battery pack over the communication channel, wherein the eighth enable message instructs the fifth battery pack to enable its converter and charge from the power bus, wherein the converter balancing technique is applied to the first battery pack and the fifth battery pack; and

A ninth enable message is sent by the master battery pack to the sixth battery pack over the communication channel, wherein the ninth enable message instructs the sixth battery pack to disable its converter and charge from the power bus, wherein the direct balancing technique is applied to the first battery pack and the sixth battery pack.

Embodiment 84. The method of embodiment 75 wherein one of the first battery pack, the fifth battery pack, and the sixth battery pack is used as the master battery pack for the battery system.

Embodiment 85 the method of embodiment 70, further comprising:

Obtaining, by the master battery pack, a current SoC value from the plurality of battery packs;

determining, by the master battery pack, whether a second subset of the plurality of battery packs require charge balancing based on the current SoC value;

selecting, by the master battery pack, a second balance type from the plurality of balance types suitable for the second subset of the plurality of battery packs, wherein the first balance type and the second balance type are different; and

A selected second balancing type is applied by the master battery pack for the second subset of the plurality of battery packs.

Embodiment 86. The method of embodiment 70 wherein the applying comprises:

Acquiring a safety interlocking indicator and a wake-up indicator; and

The application is enabled only when the safety interlock indicator indicates on and the wake-up indicator indicates off.

Embodiment 87. A first battery pack configured for installation in a battery system to power a terminal device, wherein all installed battery packs installed in the battery system have identical electrical and electronic components, the first battery pack comprising:

A communication interface circuit configured to interface to a communication channel;

a power bus interface circuit configured to interface with a power bus and provide power to the terminal device;

a controller comprising at least one processor; and

A memory storing controller instructions that, when executed by the at least one processor, cause the controller to:

when the first battery pack is used as a main battery pack of the battery system:

Collecting battery state information from a plurality of battery packs, wherein the plurality of battery packs includes the master battery pack and all slave battery packs, and wherein the battery state information includes state of charge (SoC) data;

determining, based on the battery state information, whether a first subset of the plurality of battery packs require charge balancing;

selecting a first balance type from a plurality of balance types suitable for the first subset of the plurality of battery packs; and

The selected first balancing type is applied until a desired SoC value for the first subset of the plurality of battery packs is obtained.

Embodiment 88 the first battery pack of embodiment 87, wherein the memory stores controller instructions that, when executed by the at least one processor, cause the controller to:

Identifying a first battery pack having a high SoC value from the collected battery state information; and

The high SoC value is compared with SoC values of all remaining battery packs.

Embodiment 89 the first battery pack of embodiment 88, wherein the memory stores controller instructions that, when executed by the at least one processor, cause the controller to:

in response to the comparison, when a first SoC difference between the first battery pack and a second battery pack is greater than a first predetermined amount, a converter balancing technique is initiated by the master battery pack for the first battery pack and the second battery pack.

Embodiment 90. The first battery pack of embodiment 88, wherein the memory stores controller instructions that, when executed by the at least one processor, cause the controller to:

in response to the comparison, a direct balancing technique is initiated by the master battery pack for the first battery pack and the fourth battery pack when a third SoC difference value between the first battery pack and the fourth battery pack is less than a second predetermined amount.

Embodiment 91 the first battery pack of embodiment 88, wherein the memory stores controller instructions that, when executed by the at least one processor, cause the controller to:

In response to the comparison, when a fourth SoC difference between the first battery pack and a fifth battery pack is less than a third predetermined amount, a fifth SoC difference between the first battery pack and a sixth battery pack is greater than a fourth predetermined amount, and a sixth SoC difference between the first battery pack and a seventh battery pack is greater than the fourth predetermined amount, a cross balancing technique is initiated for the first battery pack, the fifth battery pack, and the sixth battery pack.

Embodiment 92. A battery system configured to power a terminal device and including a plurality of battery packs, the battery system comprising:

A plurality of slave battery packs; and

A main battery pack, the main battery pack comprising:

a first communication interface circuit configured to interface to a Controller Area Network (CAN) bus;

a controller comprising at least one processor; and

A memory storing controller instructions that, when executed by the at least one processor, cause the controller to:

collecting battery state information from all battery packs of the battery system, wherein the all battery packs include the master battery pack and the plurality of slave battery packs, and wherein the battery state information includes state of charge (SoC) data;

Determining, based on the battery state information, whether a first subset of the total battery packs require charge balancing;

selecting a first balance type from a plurality of balance types suitable for the first subset of the total battery packs; and

The selected first balancing type is applied until a desired SoC value for the first subset of the total battery packs is obtained.

Embodiment 93 the battery system of embodiment 92, wherein the memory stores controller instructions that, when executed by the at least one processor, cause the controller to:

Identifying a first battery pack having a high SoC value from the collected battery state information, wherein the plurality; and

The high SoC value is compared with SoC values of all remaining battery packs.

Embodiment 94 the battery system of embodiment 93, wherein the memory stores controller instructions that, when executed by the at least one processor, cause the controller to:

In response to the comparison:

When a first SoC difference between the first and second battery packs is greater than a first predetermined amount, starting a converter balancing technique for the first and second battery packs;

When the first SoC difference between the first battery pack and the second battery pack is less than a second predetermined amount, initiating a direct balancing technique for the first battery pack and the second battery pack; and

When a first SoC difference between the first battery pack and the second battery pack is less than the second predetermined amount, a second SoC difference between the first battery pack and a third battery pack is greater than the first predetermined amount, and a third SoC difference between the first battery pack and a fourth battery pack is greater than the first predetermined amount, a cross balancing technique is initiated for the first battery pack, the second battery pack, the third battery pack, and the fourth battery pack.

Example 95. A method comprising:

Receiving, by a computing device having one or more processors, a first reading of a state of charge (SoC) of each of a plurality of battery packs, wherein the plurality of battery packs includes at least a first group of one or more battery packs and a second group of one or more battery packs;

Based on the received first reading of the SoC for each of the plurality of battery packs, and based on an identification of a lowest level of the first reading of the SoC and a second lowest level of the first reading of the SoC,

The first group is the lowest level having the first reading of the SoC, and

The second group is the second lowest level having the first reading of the SoC;

Generating, by the computing device, a first list comprising the first group and the second group based on the lowest level and the second lowest level of the identification;

Determining, by the computing device, a first SoC variability of the first list based on the first readings of the socs of the first group and based on the first readings of the socs of the second group;

determining, by the computing device and based on the first SoC variability, that the first SoC variability does not meet a SoC variability threshold;

establishing, by the computing device, a first SoC threshold using the first readings of the socs of the second group;

Causing, by the computing device and via a charge array, charging of the first group to cause the SoC of the first group to increase;

Receiving, by the computing device, a second reading of the SoC for each of the plurality of battery packs;

Determining, by the computing device and based on a second read of the socs of the first group, that the second read of the socs of the first group meets the first SoC threshold.

Embodiment 96 the method of embodiment 95, further comprising:

Determining, by the computing device and based on the received second readings of the socs for each of the plurality of battery packs, an updated first SoC variability for the first list;

determining, by the computing device, that the updated first SoC variability satisfies the SoC variability threshold.

Embodiment 97 the method of embodiment 95 wherein receiving the first reading of the SoC for each of the plurality of battery packs further comprises:

Identifying, by the computing device, a primary battery pack as one of the plurality of battery packs; and

The first reading of the SoC for each of the plurality of battery packs is received by the computing device and from the master battery pack.

Embodiment 98 the method of embodiment 95 wherein the causing the charging further comprises enabling a discharge array of the one or more battery packs from a charger to the first group of one or more battery packs via a converter.

Embodiment 99. The method of embodiment 95 wherein the plurality of battery packs further comprises a third group of at least one or more battery packs, and wherein the method further comprises:

Based on the received second readings of the SoC for each of the plurality of battery packs, and based on an identification of a lowest level of second readings of the SoC and a second lowest level of second readings of the SoC,

The first group and the second group are the lowest level having the second reading of the SoC, and

The third group is the second lowest level having the second reading of the SoC;

generating, by the computing device and based on the lowest level of the second reading of the SoC and the second lowest level of the second reading of the SoC, a second list comprising the first group, the second group, and the third group;

Determining, by the computing device, a second SoC variability of the second list based on the second readings of the socs of the first group, based on the second readings of the socs of the second group, and based on the second readings of the socs of the third group.

Embodiment 100. The method of embodiment 99 wherein generating the second list comprises expanding the first list to include a battery pack having the second lowest level for the second reading of the SoC.

Embodiment 101. The method of embodiment 99, further comprising:

determining, by the computing device, that the second SoC variability does not meet the SoC variability threshold;

establishing, by the computing device, a second SoC threshold based on a second reading of the socs of the third group;

causing, by the computing device and via the charge array:

the charging of the first group causes the SoC of the first group to increase, an

The charging of the second group causes the SoC of the second group to increase;

receiving, by the computing device, a third reading of the SoC for each of the plurality of battery packs;

Determining, by the computing device, that a third read of the socs of the first group and a third read of the socs of the second group each satisfy the second SoC threshold.

Embodiment 102. The method of embodiment 101 further comprising:

Performing one or more iterations of the following until the determined updated SoC variability of the plurality of battery packs meets the SoC variability threshold:

Identification by the computing device

An nth group of one or more battery packs of a plurality of battery backup devices, wherein the nth group has a lowest level of previous readings of the SoC of the plurality of battery packs, and

An (n+1) -th group of one or more battery packs of the plurality of battery backup devices, wherein the (n+1) -th group has the second lowest level of the previous readings of the SoC of the plurality of battery packs, and

Generating, by the computing device, a list including the nth group and the n+1th group;

determining, by the computing device, that the SoC variability of the list does not meet the SoC variability threshold;

Establishing, by the computing device, soC thresholds using the previous readings of the socs for the n+1 groups;

Causing, by the computing device and via a charge array, charging of the nth group to cause the SoC of the nth group to increase and satisfy the SoC threshold;

Receiving, by the computing device, subsequent readings of the SoC of each of the plurality of battery packs; and

Determining, by the computing device and based on the subsequent readings of the SoC of each of the plurality of battery packs, the updated SoC variability of the plurality of battery packs.

Embodiment 103. The method of embodiment 95 further comprising:

Before receiving the first read of the SoC of each of the plurality of battery packs, determining that an interlock safety pin associated with the plurality of battery packs is set to on, wherein the interlock safety pin allows the first read of the SoC of each of the plurality of battery packs to occur.

Embodiment 104. The method of embodiment 95 further comprising:

Before the causing the charging, determining that a wake-up pin associated with the plurality of battery packs is set to on, wherein the wake-up pin allows the charging to occur.

Embodiment 105. A method comprising:

receiving, by a computing device having one or more processors and communicatively linked to a terminal device, a power requirement of the terminal device;

a first reading of a state of charge (SoC) of each of a plurality of battery packs is received by the computing device,

Wherein the plurality of battery packs includes at least a first group of one or more battery packs and a second group of one or more battery packs, and

Wherein the first reading of the second group of socs is greater than the first reading of the first group of socs;

Determining, by the computing device and based on the received first readings of the SoC for each of the plurality of battery packs, a first SoC variability for the plurality of battery packs;

Determining, by the computing device and based on the first SoC variability not meeting a SoC variability threshold, to enable the second group to initially power the terminal device without simultaneously powering the terminal device through other battery packs of the plurality of battery packs; and

Causing, by the computing device and via a charge array, the second group to power the terminal device to a first power level, wherein the powering the terminal device causes the SoC of the second group to decrease.

Embodiment 106. The method of embodiment 105, further comprising:

Receiving, by the computing device, a second reading of the SoC of each of the plurality of battery packs; and

Determining, by the computing device and based on the received second readings of the SoC for each of the plurality of battery packs, a second SoC variability for the plurality of battery packs;

Determining, by the computing device, that the second SoC variability meets the SoC variability threshold; and

The first group and the second group are caused to power the terminal device to a second power level by the computing device and via one or more charge arrays, wherein the powering the terminal device causes the second readings of the socs of the first group and the second readings of the socs of the second group to decrease.

Embodiment 107. The method of embodiment 105, further comprising:

A second reading of the SoC for each of the plurality of battery packs is received by the computing device,

Wherein the plurality of battery packs further comprises a third group of one or more battery packs,

Wherein the second readings of the socs of the second group and the second readings of the socs of the third group are within a predetermined reading of each other, and

Wherein the second read of the SoC of the second group and the second read of the SoC of the third group are each greater than the second read of the SoC of the first group,

Determining, by the computing device and based on the received second readings of the SoC for each of the plurality of battery packs, a second SoC variability for the plurality of battery packs;

determining, by the computing device, that the second SoC variability does not meet the SoC variability threshold; and

Causing, by the computing device and via one or more charge arrays, the second group and the third group to concurrently power the terminal device to a second power level, wherein the powering the terminal device causes the SoC of the second group and the SoC of the third group to decrease.

Embodiment 108. The method of embodiment 105 wherein receiving the first reading of the SoC for each of the plurality of battery packs further comprises:

Identifying, by the computing device, a primary battery pack as one of the plurality of battery packs; and

The first reading of the SoC for each of the plurality of battery packs is received by the computing device and from the master battery pack.

Embodiment 109. A method comprising:

receiving, by a computing device having one or more processors and communicatively linked to a terminal device, a power requirement of the terminal device;

a first reading of a state of charge (SoC) of each of a plurality of battery packs is received by the computing device,

Wherein the plurality of battery packs includes at least a first group of one or more battery packs and a second group of one or more battery packs,

Wherein the first reading of the SoCs of the second group is greater than the first reading of the SoCs of the first group, and

Determining, by the computing device and based on the received first readings of the SoC for each of the plurality of battery packs, a first SoC variability for the plurality of battery packs;

Determining, by the computing device, that the first SoC variability does not meet a SoC variability threshold; and

Causing, by the computing device and via one or more charge arrays, the second group to charge the first group, wherein the charging the first group reduces the SoC of the second group and increases the SoC of the first group.

Embodiment 110 the method of embodiment 109, further comprising:

Receiving, by the computing device, a second reading of the SoC for each of the plurality of battery packs;

determining, by the computing device and based on the received second readings of the SoC for each of the plurality of battery packs, a second SoC variability for the plurality of battery packs; and

Determining, by the computing device, that the second SoC variability satisfies the SoC variability threshold.

Embodiment 111 the method of embodiment 110, further comprising:

The terminal device is powered by the computing device and via one or more charge arrays by the plurality of battery packs, wherein the powering causes the SoC of the plurality of battery packs to decrease.

Embodiment 112. The method of embodiment 109, further comprising:

receiving, by the computing device, a first reading of a state of health (SOH) of each of the plurality of battery packs, wherein the plurality of battery packs further includes a third group of one or more battery packs;

Determining, by the computing device, that the first reading of the SOH of the third group does not satisfy an SOH threshold; and

Isolating, by the computing device, the third group from powering the terminal device until subsequent readings of the SoC of each of the plurality of battery packs other than the one or more battery packs of the third group do not satisfy a SoC threshold.

Embodiment 113. The method of embodiment 109 wherein receiving the first reading of the SoC for each of the plurality of battery packs further comprises:

Identifying, by the computing device, a primary battery pack as one of the plurality of battery packs; and

The first reading of the SoC for each of the plurality of battery packs is received by the computing device and from the master battery pack.

Embodiment 114. The method of embodiment 109 wherein the second group charges the first battery pack via one or more of converter balancing, direct connection balancing, or interleaved balancing.

In some embodiments, the term "large-sized" includes middle-sized battery embodiments and use cases. For example, medium-scale and large-scale applications are realized by the extensive description herein.

Although many of the systems and methods described herein relate to lithium ion battery storage chemistry, the present disclosure is not so limited. In many cases, those of ordinary skill in the art will appreciate that other primary chemicals for rechargeable batteries may be suitably replaced with lithium ions (Li ions), nickel cadmium (Ni-Cd), nickel metal hydrides (Ni-MH), lead acid, and other chemicals without substantially departing from the spirit of the solution. For some embodiments, the battery management systems disclosed herein may be included in these technology batteries to provide battery protection, to provide improved efficiency, and to provide a better user experience than previous battery technologies. Variations of lithium cobalt cathodes, such as Nickel Cobalt Aluminum (NCA) and Nickel Manganese Cobalt (NMC), may be desirable in electric vehicles and other applications. Other novel cathode chemistries, such as lithium manganese spinel (LMO) and lithium iron phosphate (LFP), may be used where appropriate. In addition, large battery packs provide lower system integration costs, particularly because they can reduce the number of battery interconnections, further improving the reliability of the battery pack and providing higher value propositions.

Further, the combination of battery packs may include battery packs that share a common battery chemistry (e.g., all lithium ions or all Ni-Cd, etc.). Or a combination of battery packs may include different battery chemistries. The battery packs of different battery chemistries may be randomly selected or may be selected based on their functional combinations to provide a collective function. For example, a first battery pack having a first type of battery chemistry (e.g., a chemistry capable of providing a high instantaneous current but incapable of storing a large amount of energy) may be combined with a second battery pack having a second type of battery chemistry (e.g., a chemistry storing a large amount of energy but incapable of providing a high peak current) such that the combination of battery packs may provide a high initial current from the first battery pack and then a sustained, albeit lower, current from the second battery pack. Other combinations of aspects of different battery chemistries are possible and are considered to be within the scope of the present disclosure.

As will be appreciated by those skilled in the art, the exemplary embodiments disclosed herein may be implemented using a computer system having an associated computer-readable medium containing instructions for controlling the computer system. The computer system may include at least one computer, such as a microprocessor, digital signal processor, and associated peripheral electronic circuitry.

Claims (40)

1. A first battery pack configured to be mounted in a battery system of a plurality of battery packs to power a terminal device not equipped with an electronic communication apparatus, wherein the battery packs mounted in the battery system have identical electrical and electronic components, the first battery pack comprising:

one or more battery cells;

a power bus interface circuit configured to interface with a power bus and provide power to the terminal device;

a switch;

A gateway connector connected to the switch and communicatively coupled with an interface to the terminal device, the gateway connector configured to provide a signal to an input line of the terminal device;

a controller comprising at least one processor; and

A memory storing controller instructions that, when executed by the at least one processor, cause the controller to:

determining that the first battery pack is a master battery pack of the battery system;

Determining whether a first backup battery pack is available when the first battery pack receives a fault notification message indicating a catastrophic fault at a second battery pack and when additional battery packs are needed;

Disabling the second battery pack from discharging onto the power bus when no backup battery pack is available, and sending a degradation warning message to the terminal device, the degradation warning message identifying degradation of available power from the plurality of battery packs in the battery system; and

The gateway connector is triggered to output a limp home mode signal to the terminal device using the interface to the terminal device based on sending the degradation warning message to the terminal device and to cause the terminal device to operate in a degradation mode.

2. The first battery pack of claim 1, wherein the interface to the terminal device comprises a gateway Printed Circuit Board Assembly (PCBA).

3. The first battery pack of claim 1, wherein the terminal device is powered by a non-intelligent battery.

4. The first battery pack of claim 1, wherein triggering the gateway connector to output the limp home mode signal to the terminal device using the interface to the terminal device comprises causing a hardware pin corresponding to a limp home mode on the terminal device to be set.

5. The first battery pack of claim 1, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

A look-up table is stored that includes different state of charge thresholds corresponding to different temperature readings.

6. The first battery pack of claim 1, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

A lookup table is stored that includes different state of charge thresholds corresponding to different numbers of battery packs installed in the battery system.

7. The first battery pack of claim 1, wherein the first battery pack receiving the fault notification message indicating the catastrophic fault at the second battery pack is based on one or more criteria in a lookup table storing different state of charge thresholds.

8. The first battery pack of claim 1, wherein the first battery pack receiving the fault notification message indicating the catastrophic fault at the second battery pack is based on one or more battery cells of the second battery pack having a state of charge value below a predetermined threshold.

9. The first battery pack of claim 1, wherein triggering the gateway connector to output the limp home mode signal to the terminal device using the interface to the terminal device comprises controlling the switch to output a preset regulated voltage.

10. The first battery pack of claim 1, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

And when the terminal equipment does not observe the degradation alarm message, starting the shutdown of the battery system.

11. The first battery pack of claim 1, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

Transmitting an enabling message to at least one backup battery pack when the at least one backup battery pack is available and additional battery packs are needed to power the terminal device, wherein the enabling message instructs the at least one backup battery pack to discharge onto the power bus; and

Triggering the gateway connector to deactivate the limp home mode signal using the interface to the terminal device.

12. The first battery pack of claim 2, wherein the gateway Printed Circuit Board Assembly (PCBA) is configured to read state of charge (SoC) data via an electronic communication protocol.

13. A method, comprising:

determining, by the primary battery, whether the first backup battery is available after receiving a fault notification message indicating a catastrophic fault at the second battery;

Transmitting, by the primary battery, a disable message to the second battery and a degradation warning message to a terminal device when no backup battery is available and additional batteries are needed, wherein the disable message instructs the second battery to terminate discharging onto a power bus and to be transmitted by the primary battery, and wherein the degradation warning message identifies degradation of available power from a plurality of battery packs in a battery system;

Triggering a gateway connector by the main battery pack to output a limp home mode signal to the terminal device using an interface to the terminal device; and

So that the terminal device operates in a degraded mode.

14. The method of claim 13, wherein the interface to the terminal device comprises a gateway Printed Circuit Board Assembly (PCBA).

15. The method of claim 13, further comprising powering the terminal device by a non-intelligent battery.

16. The method of claim 13, wherein triggering the gateway connector to output the limp home mode signal to the terminal device using the interface to the terminal device comprises setting a hardware pin corresponding to a limp home mode on the terminal device.

17. The method of claim 13, wherein receiving the fault notification message indicating the catastrophic fault at the second battery pack is based on one or more criteria in a lookup table storing different state of charge thresholds.

18. The method of claim 13, wherein receiving the fault notification message indicating the catastrophic fault at the second battery pack is based on one or more battery cells of the second battery pack having a state of charge value below a predetermined threshold.

19. The method of claim 13, wherein triggering the gateway connector to output the limp home mode signal to the terminal device using the interface to the terminal device comprises controlling a switch to output a preset regulated voltage.

20. A battery system configured to power a terminal device and including a plurality of battery packs, the battery system comprising:

a slave battery pack; and

A main battery pack, the main battery pack comprising:

a switch;

A gateway connector connected to the switch and communicatively coupled with an interface to the terminal device, the gateway connector configured to provide a signal to an input line of the terminal device;

a controller comprising at least one processor; and

A memory storing controller instructions that, when executed by the at least one processor, cause the controller to:

Determining whether a first backup battery pack is available when the primary battery pack receives a fault notification message indicating a catastrophic fault at a second battery pack and when additional battery packs are needed;

disabling the second battery pack from discharging onto a power bus when no backup battery pack is available, and sending a degradation warning message to the terminal device, the degradation warning message identifying degradation of available power from the plurality of battery packs in the battery system; and

The gateway connector is triggered to output a limp home mode signal to the terminal device using the interface to the terminal device based on sending the degradation warning message to the terminal device and to cause the terminal device to operate in a degradation mode.

21. A first battery pack configured to be mounted in a battery system of a plurality of battery packs to power a terminal device not equipped with an electronic communication apparatus, wherein the battery packs mounted in the battery system have identical electrical and electronic components, the first battery pack comprising:

a power bus interface circuit configured to interface with a power bus and provide power to the terminal device;

a switch;

A gateway connector connected to the switch and communicatively coupled with an interface to the terminal device, the gateway connector configured to provide a signal to an input line of the terminal device;

a controller comprising at least one processor; and

A memory storing controller instructions that, when executed by the at least one processor, cause the controller to:

determining that the first battery pack is a master battery pack of the battery system;

Collecting battery state information from the plurality of battery packs, wherein the plurality of battery packs includes the master battery pack and a plurality of slave battery packs, and wherein the battery state information includes state of charge (SoC) data;

selecting a highest state of charge (SoC) slave battery pack from the plurality of slave battery packs based on the battery state information, wherein the highest SoC slave battery pack is characterized by a highest SoC value of the plurality of slave battery packs;

determining whether the highest SoC slave battery pack is in a fully charged state based on the battery state information; and

When the highest SoC slave battery pack is in the full charge state, the gateway connector is triggered to output a full charge signal to the terminal device using the interface to the terminal device and cause the interface to the terminal device to notify a charger of the full charge state.

22. The first battery pack of claim 21, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

When the highest SoC slave battery pack is not in the full charge state, the gateway connector is triggered to deactivate the full charge signal to the terminal device using the interface to the terminal device.

23. The first battery pack of claim 21, wherein the interface to the terminal device comprises a gateway Printed Circuit Board Assembly (PCBA) configured to read the SoC data via an electronic communication protocol.

24. The first battery pack of claim 21, wherein the terminal device is powered by a non-intelligent battery.

25. The first battery pack of claim 21, wherein the full charge signal output by the gateway connector to the terminal device drives a Light Emitting Diode (LED).

26. The first battery pack of claim 21, wherein the full charge signal output by the gateway connector is connected to an application controller of the terminal device.

27. The first battery pack of claim 21, wherein triggering the gateway connector to output the full charge signal to the terminal device using the interface to the terminal device comprises controlling the switch to output a preset regulated voltage.

28. The first battery pack of claim 21, wherein the controller instructions, when executed by the at least one processor, further cause the controller to:

the SoC value for each of the plurality of battery packs is continuously calculated using one or more algorithms.

29. The first battery pack of claim 21, wherein the charger is one of a plurality of chargers connected in parallel to charge the plurality of battery packs.

30. The first battery pack of claim 21, wherein the full charge state identifies one hundred percent SoC.

31. A method, comprising:

Collecting, by a master battery pack, battery state information from a plurality of battery packs, wherein the plurality of battery packs includes the master battery pack and a plurality of slave battery packs, and wherein the battery state information includes state of charge (SoC) data;

Selecting, by the master battery pack, a highest state of charge (SoC) slave battery pack from the plurality of slave battery packs based on the battery state information, wherein the highest SoC slave battery pack is characterized by a highest SoC value of the plurality of slave battery packs;

Determining, by the master battery pack, whether the highest SoC slave battery pack is in a fully charged state based on the battery state information; and

When the highest SoC slave battery pack is in the fully charged state, a gateway connector is triggered by the master battery pack to output a fully charged signal to a terminal device using an interface to the terminal device and cause the interface to the terminal device to notify a charger of the fully charged state.

32. The method of claim 31, further comprising:

When the highest SoC slave battery pack is not in the fully charged state, the gateway connector is triggered by the master battery pack to deactivate the fully charged signal to the terminal device using the interface to the terminal device.

33. The method of claim 31, wherein the interface to the terminal device comprises a gateway Printed Circuit Board Assembly (PCBA) configured to read the SoC data via an electronic communication protocol.

34. The method of claim 31, wherein the terminal device is powered by a non-intelligent battery.

35. The method of claim 31, further comprising:

Light Emitting Diodes (LEDs) are driven by the full charge signal output by the gateway connector to the terminal device.

36. The method of claim 31, wherein triggering the gateway connector to output the full charge signal to the terminal device using the interface to the terminal device comprises controlling a switch to output a preset regulated voltage.

37. The method of claim 31, further comprising:

the SoC value for each of the plurality of battery packs is continuously calculated using one or more algorithms.

38. The method of claim 31, wherein the full charge state identifies one hundred percent SoC.

39. A battery system configured to power a terminal device and including a plurality of battery packs, the battery system comprising:

a slave battery pack; and

A main battery pack, the main battery pack comprising:

a switch;

A gateway connector connected to the switch and communicatively coupled with an interface to the terminal device, the gateway connector configured to provide a signal to an input line of the terminal device;

a controller comprising at least one processor; and

A memory storing controller instructions that, when executed by the at least one processor, cause the controller to:

Collecting battery state information from the plurality of battery packs, wherein the plurality of battery packs includes the master battery pack and a plurality of slave battery packs, and wherein the battery state information includes state of charge (SoC) data;

selecting a highest state of charge (SoC) slave battery pack from the plurality of slave battery packs based on the battery state information, wherein the highest SoC slave battery pack is characterized by a highest SoC value of the plurality of slave battery packs;

determining whether the highest SoC slave battery pack is in a fully charged state based on the battery state information; and

When the highest SoC slave battery pack is in the full charge state, the gateway connector is triggered to output a full charge signal to the terminal device using the interface to the terminal device and cause the interface to the terminal device to notify a charger of the full charge state.

40. The battery system of claim 39, wherein the interface to the terminal device comprises a gateway Printed Circuit Board Assembly (PCBA) configured to read the SoC data via an electronic communication protocol.