WO2019236869A1 - Noise-immune battery pack communication system and applications thereof - Google Patents

Noise-immune battery pack communication system and applications thereof Download PDF

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Publication number
WO2019236869A1
WO2019236869A1 PCT/US2019/035822 US2019035822W WO2019236869A1 WO 2019236869 A1 WO2019236869 A1 WO 2019236869A1 US 2019035822 W US2019035822 W US 2019035822W WO 2019236869 A1 WO2019236869 A1 WO 2019236869A1
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WO
WIPO (PCT)
Prior art keywords
battery
controller
optical fiber
communication system
battery pack
Prior art date
Application number
PCT/US2019/035822
Other languages
French (fr)
Other versions
WO2019236869A9 (en
Inventor
Virgil Lee BEASTON
Patrick Joseph Nystrom
Original Assignee
Beaston Virgil Lee
Patrick Joseph Nystrom
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Beaston Virgil Lee, Patrick Joseph Nystrom filed Critical Beaston Virgil Lee
Publication of WO2019236869A1 publication Critical patent/WO2019236869A1/en
Publication of WO2019236869A9 publication Critical patent/WO2019236869A9/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/44—Methods for charging or discharging
    • H01M10/441—Methods for charging or discharging for several batteries or cells simultaneously or sequentially
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • H01M50/24—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries from their environment, e.g. from corrosion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/482—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for several batteries or cells simultaneously or sequentially
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/486—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for measuring temperature
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/251—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for stationary devices, e.g. power plant buffering or backup power supplies
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/42—Coupling light guides with opto-electronic elements
    • G02B6/4201—Packages, e.g. shape, construction, internal or external details
    • G02B6/4204—Packages, e.g. shape, construction, internal or external details the coupling comprising intermediate optical elements, e.g. lenses, holograms
    • G02B6/4214—Packages, e.g. shape, construction, internal or external details the coupling comprising intermediate optical elements, e.g. lenses, holograms the intermediate optical element having redirecting reflective means, e.g. mirrors, prisms for deflecting the radiation from horizontal to down- or upward direction toward a device
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H01M2010/4278—Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • Embodiments disclosed herein generally relate to electrical energy storage. More specifically, they relate to a battery cell communication system that may include elements to immunize the system from electromagnetic and other interference.
  • Electromagnetic interference is a common type of noise that occurs in energy storage systems and can reduce the reliability and/or stability of these systems. Switching noise from power converters is also another source of noise in energy storage systems that can reduce their reliability and/or stability.
  • references to“one embodiment,”“an embodiment,”“an example embodiment,” etc. indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
  • the present disclosure provides a battery cell communication system
  • the electrical energy storage unit includes a battery pack controller and battery groups.
  • Each battery group has battery cells and a battery group controller to monitor the cells.
  • Battery cells comprise individual batteries.
  • battery cells of the present invention may include (but are not limited to) lithium-ion batteries.
  • Each battery group controller may include charging terminals and resistors that are used to charge or discharge, respectively, energy stored in the battery cells of the respective battery group.
  • the battery group controller monitors information about the battery group to which the battery group controller is coupled.
  • the battery group controller may include a communication hub comprising a communication source, coupled to a microprocessor, that transmits the information about the battery group coupled to the battery group controller.
  • the battery pack controller includes a processing unit and a battery pack communication controller. The battery pack controller may control the state-of-charge of the battery cells.
  • a battery group controller is optically isolated by a
  • communication hub comprising a communication source, coupled to a microprocessor, that transmits information about the battery group coupled to the battery group controller, and utilizing a physical layer of a communications network that is immune to noise, such as electromagnetic interference and power converter switching noise.
  • the communication hub of a battery group controller is coupled to the battery pack controller as a component of an optical fiber communication network that provides a channel to communicate data in the form of light from the battery pack controller to the battery group controller.
  • a battery pack communication controller includes an optical fiber connector configured to communicate with at least two battery group controllers.
  • the battery pack communication controller may send signals to battery group controllers for processing.
  • a battery group may refer to a plurality of battery cells.
  • a non-limiting example of a battery group includes 4 battery cells.
  • a battery pack may refer to a plurality of battery groups, which are connected in a network.
  • a non-limiting example of a battery pack includes 12 to 16 battery groups.
  • microprocessor or“processor” as used herein may refer to, be
  • a machine such as a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed and programmed to perform or cause the performance of the functions described herein.
  • DSP digital signal processor
  • ASIC application specific integrated circuit
  • FPGA field programmable gate array
  • a general-purpose processor or microprocessor can alternatively be a microcontroller, or state machine, combinations of the same, or the like.
  • microprocessor can also be implemented as a combination of computing devices.
  • FIGS. 1 A and 1B are diagrams illustrating an example BESS coupled to a bi directional power converter.
  • FIGS. 2A and 2B are diagrams illustrating an example BESS.
  • FIGS. 3A, 3B, and 3C are diagrams illustrating an example BESS housed in a modified shipping container.
  • FIGS. 4A, 4B, 4C, and 4D are diagrams illustrating an example modular, stackable BESS.
  • FIGS. 5A, 5B, 5C, 5D, and 5E are diagrams illustrating an example modular, stackable battery stack.
  • FIG. 6 is a diagram illustrating air flow in an example BESS.
  • FIGS. 7A, 7B, 7C, 7D, 7E, and 7F are diagrams illustrating an example modular, stackable battery pack or battery unit.
  • FIGS. 8A, 8B, and 8C are diagrams showing an example modular, stackable
  • FIGS. 9A, 9B, and 9C are diagrams showing an example battery assembly for a modular, stackable battery pack.
  • FIGS. 10A and 10B are diagrams showing an example battery stack controller.
  • FIG. 11 is a diagram illustrating an example battery pack communication system.
  • FIG. 12 is a diagram illustrating an example battery pack communication system.
  • FIG. 13 is a diagram illustrating an example optically isolated battery group
  • FIGS. 14 and 15 are diagrams illustrating exemplary connectors in a battery pack communication system.
  • FIGS. 16A and 16B are diagrams illustrating a communication hub and a
  • FIGS. 17A, 17B, 17C, and 17D are images illustrating an example battery pack controller.
  • FIG. 18 is an image illustrating an example battery pack communication system.
  • an energy storage system may include inverters capable of both charging a battery group and discharging the battery group using commands issued, for example, via a computer over a network (e.g. the Internet, an Ethernet, et cetera) as described in more detail below.
  • inverters can be operated as a backup power source when grid power is not available and/or electrical energy storage unit is disconnected from the grid.
  • inverter e.g. a DC source, a solar panel or a battery
  • inrush current or surge
  • a large enough surge may potentially destroy the capacitors and create a fire in the inverter.
  • inverters are particularly vulnerable.
  • the risks of damage caused by electromagnetic interference is especially a concern in energy storage systems.
  • Batteries, unlike solar panels for example, have low impedance. Therefore, a short circuit in a battery may create a very large current, potentially measuring in the range of several thousands of amps. Such current is substantially greater than the current in a similar size solar panel, which has a higher internal impedance.
  • the systems and methods disclosed herein provide an EMI and noise-immune battery pack communication system to minimize problems caused by electromagnetic and other interference.
  • the battery pack communication system avoids reliance on electrical conductors prone to EMI for carrying instructions and/or information.
  • a battery pack communication system can integrate freely with any type of electrical inverter and operate even in the absence of filters or isolation transformers.
  • a battery group controller monitors and controls a subset of the battery cells that form one or more battery groups.
  • the battery group controllers are networked and operate together as part of a communication network of battery group controllers.
  • a battery pack may include a network of battery group controllers that control the battery cells included in the battery pack.
  • a plurality of battery packs may be linked together to form a battery energy storage system, such as a multi -megawatt-hour centralized battery energy storage system.
  • one or more of the networked battery group controllers can operate to control battery charge and discharge operations by sending commands that operate one or more inverters and/or chargers connected to the battery groups.
  • the commands to operate inverters and/or chargers are communicated to a battery pack controller via an optical connector, such as optical fiber or the like.
  • each battery group controller may be coupled to or may
  • the communication hub provides a communication path or channel for an optical signal to communicate commands and information between the one or more networked battery group controllers and a battery pack controller.
  • a battery pack communication system may be included in a stackable battery pack included in a battery energy storage system (BESS). Exemplary illustrations of BESS housings and applications are described below. A plurality of battery packs may be stacked one on top of the other, forming a battery stack.
  • BESS battery energy storage system
  • FIGS. 1 A and 1B are diagrams illustrating an example BESS 100 coupled to a bi- directional power converter 102.
  • BESS 100 may include two external HVAC units l04a and l04b.
  • bi-directional power converter 102 may be capable of both charging and discharging the plurality of battery packs residing in BESS 100 using commands issued, for example, via a computer over a network (e.g. the Internet, an Ethernet, etc.), such as by an operator at an energy monitoring station.
  • a network e.g. the Internet, an Ethernet, etc.
  • FIG. 1B is a more detailed view of BESS 100. As shown in FIG. 1B, in an
  • BESS 100 may have several doors 106 that may be opened to gain access to battery stacks 108.
  • Battery stacks 108 may be installed inside BESS 100 and removed from BESS 100 using a forklift vehicle (not shown). This enables each battery stack 108 to be assembled external to BESS 100 and transported and installed as a single unit.
  • FIGS. 2A and 2B are diagrams further illustrating BESS 100 according to an
  • FIG. 2 A illustrates a rear view of BESS 100 with doors 106 closed
  • FIG. 2B illustrates a rear view of BESS 100 with doors 106 open.
  • FIGS. 3A, 3B, and 3C are diagrams illustrating another view of BESS 100 with its roof removed and doors 106 open.
  • BESS 700 is shown with several battery stacks 108 installed.
  • BESS 100 also may include switchgear 110, which is located at one end of BESS 100.
  • FIG. 3B illustrates a more detailed view of switchgear 110, according to an
  • FIG. 3C illustrates another view of BESS 100 including switchgear 110 located at one end of BESS 100, according to an embodiment.
  • FIGS. 4A, 4B, 4C, and 4D are diagrams illustrating various example modular, stackable BESS systems according to embodiments.
  • FIG. 4A illustrates a BESS 400 having fifteen battery stacks 108, an AC switchgear unit 402, and a DC switchgear unit 404.
  • each battery stack 108 may be assembled externally and installed as a single unit into BESS 400.
  • FIG. 4B illustrates a BESS 420 having nine battery stacks 108, an AC switchgear unit 402, and a DC switchgear unit 404.
  • FIG. 4C illustrates a BESS 120 having five battery stacks 108, an AC switchgear unit 402, and a DC switchgear unit 404.
  • FIG. 4D illustrates a BESS 430 having seven battery stacks 108, an AC switchgear unit 402, and a DC switchgear unit 404.
  • FIGS. 5A, 5B, 5C, 5D, and 5E are diagrams illustrating a modular, stackable
  • Battery stack 108 has a battery stack controller 502 and seventeen battery packs 504.
  • Plexiglass shields 506 protect the faces of battery stack controller 502 and the battery packs 504.
  • Battery stack 108 has a base 508 that enables battery stack 108 to be lifted and moved using a forklift vehicle (not shown) or similar equipment.
  • FIG. 5B illustrates another view of a battery stack 108 with plexiglass shields 506 removed, according to an embodiment.
  • FIG. 5C is an exploded view of a battery stack 520, according to an embodiment.
  • battery stack 520 may have a battery stack controller 502, nine battery packs 504, and a battery stack base 508.
  • FIG. 5D is another exploded view of battery stack 520 that further illustrates battery stack base 508, according to an embodiment.
  • FIG. 5E is a view of battery stack 108 that further illustrates battery stack base 508, according to an embodiment.
  • FIG. 6 illustrates another front view of an example BESS 600 and depicts air flow in BESS 600.
  • the BESS 600 of FIG. 6 includes a plurality of battery packs, as described in detail below (but is not limited thereto).
  • Fans in the ceiling panels of BESS 600 blow hot air from hot air region 610 above the ceiling toward the floor of BESS 600.
  • An A/C unit at the back of BESS 600 draws the hot air out of BESS 600 and provides cool air to the interior of BESS 600, creating cool air region 620.
  • the cool air regulates the temperature of the battery packs housed in BESS 600, and raises to hot air region 610 as it cools the battery packs.
  • FIGS. 7A, 7B, 7C, 7D, 7E, and 7F are diagrams illustrating a modular, stackable battery pack 504 (also referred to herein as a battery unit), according to embodiments.
  • Battery pack 504 may function similarly to and include similar structure as battery pack controller 1201 of FIG. 12, as discussed in detail below.
  • FIG. 7A shows battery pack 504 with the plexiglass shield 506 installed.
  • FIG. 7B shows battery pack 504 with the plexiglass shield 506 removed.
  • battery pack 504 has a battery pack control unit 702. The functions and structure of a battery pack control unit 702 or battery pack controller are described above.
  • FIG. 7C illustrates another view of battery pack 504 with the top removed.
  • FIG. 7D illustrates a view of battery pack 504 with the housing removed in order to better see the battery cells 704 used in battery pack 504.
  • FIG. 7E illustrates a view of battery pack 504 with battery pack control unit 702 removed. As shown in FIG. 7E, battery pack 504 may include two battery assemblies 7l0a and 710b.
  • FIG. 7F illustrates another view of a battery assembly 710.
  • FIGS. 8A, 8B, and 8C are diagrams further illustrating modular, stackable battery pack 504, according to embodiments.
  • FIG. 8A shows battery pack 504 with plexiglass shield 506 installed.
  • FIG. 8B is an exploded view of battery pack 504 showing plexiglass shield 506, battery pack control unit 702, and battery assemblies 7l0a and 7l0b. These components of battery pack 504 may be housed in a battery pack housing 802.
  • FIG. 8C is another exploded view of battery pack 504 showing plexiglass shield 506, battery pack control unit 702, and battery assemblies 7l0a and 7l0b.
  • FIGS. 9A, 9B, and 9C are diagrams further illustrating a battery assembly 710 for a modular, stackable battery pack 504, according to embodiments.
  • battery assembly 710 includes battery cells 704, battery group control units 902, and bus bars 904.
  • Each battery group control unit 902 may monitor and control two groups of battery cells, wherein each group of battery cells comprises one or more battery cells 704 connected in parallel.
  • the functions and structure of a battery group control unit 902 (also referred to as a battery group controller) are described in more detail in embodiments below.
  • FIG. 9B is an exploded view of a battery assembly 710.
  • each battery assembly 710 has four battery group control units 902.
  • FIG. 9C is a more detailed view of a battery group control unit 902.
  • Battery group control unit 902 may function similarly to and include similar structure as battery group controllers described in detail below.
  • FIGS. 10A and 10B are diagrams illustrating an example battery stack controller
  • FIG. 10A battery stack controller 502 is shown with plexiglass shield 506 installed.
  • FIG. 10B is an exploded view of battery stack controller 502.
  • FIG. 11 is a diagram illustrating an example battery pack 1100.
  • battery pack 1100 in the battery pack communication system, battery pack 1100 includes a battery pack controller 1101 coupled to battery group controllers 1110.1 to 1110. n via connectors 1130.1 to 1130. n, respectively.
  • Battery pack controller 1101 and battery group controllers 1110.1 to 1110. n are connected in a daisy-chain topology in this example embodiment.
  • each battery group controller 1110 controls a pair of boards each controlling a battery group, and sharing a single microprocessor and communication hub.
  • the layout of the present disclosure may include a microprocessor sitting across two boards, and the voltage difference across charge terminals of the respective boards may be substantial.
  • the communication system described in this disclosure utilizes an EMI and noise-immune channel, such as optical fiber, to avoid signal distortion.
  • the battery group controller layout allows other topologies, such as a star network.
  • FIG. 12 is a diagram that illustrates components of an example battery pack
  • the battery pack communications system of FIG. 12 includes a battery pack controller 1201.
  • battery pack communication system As shown in FIG. 12, in an embodiment, battery pack communication system
  • 1200 may include a battery pack controller 1201 having a processing unit 1202, that includes a microprocessor, and a battery pack communication controller 1203.
  • the battery pack communication system 1200 may additionally include battery group controllers 1210.1 to 1210. n.
  • Battery group controllers 1210.1 to 1210. n are connected to battery pack communication controller 1203 via connectors 1230.1 to 1230. n, respectively.
  • battery group controller 1210.1 is connected to battery pack communication controller 1203 via connector 1230.1.
  • Connectors 1230.1 to 1230. n may be configured to permit communication in a physical layer that is unaffected by electromagnetic interference or power converter switching noise, for example. While FIG. 12 shows at least four battery group controllers, the battery pack communication system is not limited to this number of battery group controllers and may include any number of battery group controllers.
  • Connectors 1230 may be optical fiber, for example.
  • An optical fiber generally may comprise glass having an outer cladding layer and an internal core made from silica or Germania, for example.
  • the optical fiber may be formed of plastic.
  • Photons of light emitted into one end of the optical fiber are reflected through the optical fiber until reaching the other end of the optical fiber.
  • the battery pack communication system 1200 may be implemented using either single-mode fiber or multi-mode fiber.
  • Battery pack communication controller 1203 may be coupled to processing unit
  • n may include a hub or communication connector 1204 to fix or install n connectors 1230.1 to 1230. n to the battery pack communication controller 1203.
  • Communication connector 1204 may couple connectors 1230 to a transceiver of the battery pack communication controller to send and receive communications via the connectors.
  • a transceiver may include a communication source, such as an LED, and a communication receiver, such as a photodiode. Thus, the transceiver may act as a transducer.
  • Each battery group controller 1210.1 to 1210. n may be coupled to a respective battery group. Alternatively, each battery group controller 1210.1 to 1210. n may be coupled to a plurality of battery groups (such as two battery groups). Each battery group controller 1210.1 to 1210. n may include a microprocessor and various sensors, such as one or more voltage sensors for monitoring voltage levels, and/or one or more
  • temperature sensor for monitoring temperature data of the respective battery group (e.g., microprocessor 1326 and sensors 1327 and 1328, as illustrated in the example
  • each battery group controller 1210.1 to 1210. n may be coupled to a corresponding connector 1230.1 to 1230. n by n communication hubs 1220.1 to 1220. n, which may be mounted on or part of the respective battery group controller 1210.1 to 1210. n.
  • Each communication hub 1220 may couple the connector to a transceiver of each respective battery group controller 1210 to permit communication signals to be transmitted and received without interference, such as EMI or power converter switching noise.
  • battery group controllers 1210.1 to 1210. n may provide power to any or all of the microprocessor, sensors, or communication source by transferring stored energy from one or more battery cell of the associated battery group. Therefore, an efficient communication coupling mechanism may be provided, as described below, to efficiently couple the communication source to a communication path to reduce attenuation and minimize energy conserved by the communication source.
  • Battery pack controller 1201 may include or be coupled to a balancing charger, which may be a power supply, such as a DC power supply, and may provide energy to all of the battery groups in a battery pack.
  • a balancing charger such as a DC power supply
  • battery pack controller 1201 may provide energy to all of the battery cells in the battery pack at the same time.
  • battery pack controller 1201 can, via the noise free communication channel, instruct battery group controllers 1210.1 to 1210. n to selectively discharge energy from the battery cells that are included in the one or more battery groups that they respectively control.
  • Battery group controllers 1210.1 to 1210. n may also take measurements (e.g., voltage and temperature) of the respective one or more battery groups.
  • the battery pack controller 1201 may operate charging and discharging components (described in detail below) to control the state-of- charge of the cells.
  • Battery pack controller 1201 may further include a buffer to temporarily store data and commands until such information can be processed or transmitted.
  • Battery pack controller 1201 may utilize a serial communication protocol or the like to communicate signals to battery group controllers 1210.1 to 1210. n.
  • battery pack communication system 1200 includes a plurality of
  • n battery group controllers (where n is greater than or equal to 2) can be coupled, for example, in a star topology.
  • each battery group controller may have a unique address and the battery pack controller 1201 may communicate with each of the battery group controllers 1210.1 to 1210. n by addressing one or more messages to the unique address of any desired battery group controller.
  • the one or more messages (which include the unique address of the battery group controller) may include an instruction, for example, to remove energy from a battery module, to stop removing energy from a battery module, to measure and report the temperature of the battery module, and to measure and report the voltage of the battery module.
  • battery pack controller 1201 may obtain measurements (e.g., temperature, voltage) from each of the battery group controllers using a polling technique.
  • Battery pack controller 1201 may calculate or receive (e.g., from a controller outside of battery cell communication system 1200) a target voltage for the battery pack, and may adjust each of the battery groups to the target voltage.
  • battery cell communication system 1200 may be considered a smart battery pack, able to self-adjust its battery cells to a target voltage.
  • each battery group may have a unique address and the battery pack controller 1201 may communicate with the battery group controller 1220 by addressing one or more messages directed to control of one or more individual battery groups.
  • FIG. 13 is a diagram illustrating an example battery pack controller connected to a battery group controller.
  • Battery pack controller 1301 may receive commands or information from an outside system.
  • Battery pack controller 1301 may further include a battery pack communication controller having communication connector 1304 to transmit signals to battery group controller 1310 and to receive signals.
  • Battery group controller 1310 includes a microprocessor 1326 and various sensors
  • Battery group controller 1310 may further include a communication hub 1320, for example, to send and receive signals, including sensor data and commands.
  • battery pack controller 1301 may instruct one battery group to discharge.
  • battery group controller 1310 may receive discharge energy through positive terminal 1312 and negative terminal 1313.
  • Battery pack controller 1301 which may be a battery pack controller as discussed above with respect to FIG. 12 comprising a processing unit and a battery pack communication controller, may in embodiments instruct a battery group to charge or transfer energy.
  • battery group controller 1310 may utilize a discharging element, such as shunt resistors 1315, to discharge stored energy.
  • a discharging element such as shunt resistors 1315
  • battery group controller 1310 can be configured utilizing two circuit boards 1310A and 1310B, each controlling a distinct battery group with independent sensors, discharge element(s) (e.g., shunt resistors) and battery cell terminals. Boards 1310A and 1310B are integrated as a single battery group controller. The boards share a single microprocessor and communication hub 1320 in this embodiment.
  • FIGS. 14 and 15 are diagrams illustrating exemplary connectors in a battery pack communication system.
  • a battery pack communication controller 1403 may be connected via an EMI and noise-immune communication channel to communication hubs (e.g., 1420.1 of FIG. 14) mounted on battery group controllers.
  • communication hubs e.g., 1420.1 of FIG. 14
  • a transceiver e.g. a transducer
  • battery pack communication controller 1403 is linked to n communication hubs 1420.1 to 1420. n, each of which is mounted on or part of a battery group controller.
  • optical fiber 1430 is fixed atop optical fiber connector 1404, such that a communication source (e.g. LED) of the transceiver is positioned substantially underneath the optical fibers.
  • a communication source e.g. LED
  • fixing the optical fibers atop of the connector allows the connections to be coupled directly or nearly directly over the communication source. Therefore, an advantage of this configuration is that light dispersion is minimized even for a topology involving many connections to a central host (e.g., a star topology).
  • communication hubs 1420.1 to 1420 Whereas communication hubs 1420.1 to 1420.
  • optical fiber connector 1404 needs to generate light intensity sufficient to transmit an optical signal to the communication hub of each battery group controller. Therefore, optical fibers 1430 are fixed over the communication source to minimize light dispersion.
  • optical fibers 1430 may be inserted through the sides of optical fiber connector 1504 and through the sides of communication hubs 1520.1 to l520.n.
  • Optical fiber connector 1504 may be cylindrically shaped, in this embodiment, to reduce and equalize the optical path between a communication source of battery pack communication controller 1503 and each optical fiber 1530.
  • optical fiber connector 1504 may also be implemented as a half or semi-cylindrical shape or the like or any other shape.
  • Optical fiber provides another advantage in that it is easy to fix to the communication hub, e.g., by press-fit or by adhesive.
  • a tapered hole or cavity may be provided, for example, for each optical fiber within the casing of optical fiber connector 1404 of FIG. 14 or 1504 of FIG. 15.
  • a tapered hole or cavity may also be provided, for example, in communication hubs 1520.1 to l520.n.
  • optical fibers may be fixed by an adhesive or the like.
  • Optical fibers do not suffer from, for example, metal corrosion or solder joint failures. Therefore, in addition to inoculating the battery cell communication system from electromagnetic interference and power converter switching noise, the configuration as described above may provide an advantage in reducing connectivity issues.
  • a battery pack communication system may be configured in a star topology (e.g., spoke and hub).
  • the system may alternatively be arranged in a daisy-chained topology, if a sufficiently intense light source is provided in battery pack communication controller 1403 and/or optical fiber having sufficiently low attenuation.
  • a daisy chain arrangement may allow optical fiber connector 1404 of FIG. 14 or 1504 of FIG. 15 and associated optical fiber (1430 of FIG. 14 or 1530 of FIG. 15) to be simplified to provide a single optical fiber port.
  • the transceiver of battery pack communication controller 1403 may be a chip mounted to the surface of the controller.
  • the transceiver may be integrated with the battery pack communication controller 1403 as a printed circuit board or other component of the battery pack communication controller 1403.
  • transceiver may be integrated with the battery pack communication controller while other components of the transceiver may constitute a separate printed circuit board that attaches to the battery pack communication controller.
  • processing unit 1202 and battery pack communication controller 1203 are shown as separate elements of battery pack controller 1201, e.g., in FIG. 12.
  • these elements may also be integrated together, for example, in a single printed circuit board.
  • optical fiber 1430 of FIG. 14 or 1530 of FIG. 15 There is no specific constraint on the length or other dimension of the optical fibers (i.e., optical fiber 1430 of FIG. 14 or 1530 of FIG. 15). However, the dimensions should be suitable to allow a sufficient light intensity to reach a target controller for proper communications.
  • FIGS. 16A and 16B are diagrams illustrating a cross section of an example
  • the communication hub 1620 of a battery pack communication system Efficient and functional optical networks modulate light to reach the receiver with enough power to be demodulated correctly. Improper connectors and optical components may cause a reduction in optical power of the transmitted signal, i.e., attenuation.
  • the communication hub described herein provides a path for optical signals with sufficient light intensity to ensure proper communications.
  • the communication hubs described with respect to FIG. 14 and FIG. 15 may be implemented as discussed with respect to FIG. 16A and 16B.
  • the communication hub 1620 may include an optical fiber coupler housing 1621 and an optical fiber coupler reflector 1622.
  • Each of the optical fiber coupler housing 1621 and the optical fiber coupler reflector 1622 may comprise, for example, plastic.
  • the housing and reflector couple light from optical fiber 1630 to transceiver 1611, providing a communication channel for an optical signal to be transmitted and received by the transceiver via the optical fiber.
  • optical fiber coupler housing 1621 and the optical fiber coupler reflector 1622 may be formed as a single component.
  • a reflective coating may be applied to the component to couple light between the optical fiber and transceiver 1611.
  • Transceiver 1611 may transform an optical signal into an electrical signal, and provide a resulting electrical signal to a microprocessor of battery group controller 1610. Likewise, transceiver 1611 may transform an electrical signal of battery group controller 1610 into an optical signal, and transmit the optical signal via the communication hub. Thus, transceiver 1611 may include a communication source, such as an LED, and a light receiver, such as a photodiode. Thus, the transceiver may act as a transducer.
  • Communication hub 1620 provides optical fiber coupler housing 1621 that is fixed to battery group controller 1610 by at least fixing mechanism 1623.
  • fixing mechanism 1623 may be a snap or push-in rivet that fixes optical fiber coupler housing 1621 to battery group controller 1610.
  • optical fiber coupler housing 1621 may be joined through any of a variety of mechanical fasteners, including at least one of a bolt, a screw, an adhesive, an interference fit, press-fit, etc.
  • FIG. 16B is a diagram further illustrating an example optical coupler of a battery pack communication system. As shown in 16B, optical fiber coupler housing 1621, for example, has a void 1625 that may be fitted to transceiver 1611.
  • Optical fiber coupler housing 1621 When optical fiber coupler housing 1621 is fixed to battery group controller 1610, transceiver 1611 is securely coupled within the void of optical fiber coupler housing 1621.
  • Optical fiber coupler housing 1621 also may include a cavity 1624 in which an optical fiber 1630 can be coupled. Optical fiber 1630 may be secured in cavity 1624 by press-fit, adhesive, and the like. As shown, cavity 1624 may optionally be tapered to enable the optical fiber to be secured by press-fit. Alternatively, the optical fiber may be formed integrally with the optical fiber coupler housing 1621.
  • Optical fiber coupler reflector 1622 may include a reflective surface facing void 1625 and cavity 1624. The reflector is provided at an angle such that incident light may be reflected from the optical fiber 1630 joined with cavity 1624 in a direction toward void 1625 and vice versa. An optical signal is communicated to and from battery pack controller 1601 by optical fiber 1630.
  • Optical fiber coupler reflector 1622 is illustrated as a component separate from optical fiber coupler housing 1621. The reflector and the housing may be securely fastened together to avoid vibration and/or light attenuation.
  • the optical fiber coupler reflector 1622 may be mounted on the slanted surfaces of optical fiber coupler housing 1621 by an adhesive or the like. The components are provided separately to facilitate mounting and dismounting.
  • the optical fiber coupler housing 1621 and the optical fiber coupler reflector 1622 may be fabricated integrally as a single component.
  • the transceiver 1611 may be integrated with the battery group controller 1610 either as an integrated printed circuit board, or as a component of the battery group controller 1610. Additionally or alternatively, some components of the transceiver 1611 may be integrated with the battery group controller 1610 while other components of the transceiver 1611 may constitute a separate printed circuit board that attaches to the battery group controller 1610.
  • the battery group controller 1610 includes a microprocessor capable of
  • a post- amplifier may be coupled to the transceiver 111 and/or to battery group controller 1610 to amplify the optical signal and provide an amplified signal to the battery group controller 110
  • An optical signal may be modulated and demodulated by transceiver 1611, e.g., converted into digital bits. For example, light directed to transceiver 1611 may be interpreted as a 1 whereas an absence of light may be interpreted as a 0.
  • an optical signal may contain information in a syntax similar to that of a corresponding electrical signal, but for the physical layer.
  • the optical signal may be in the form of light in a visible wavelength range (e.g., 430 to 770 THz). Additionally or alternatively, the signal may include light in the infrared wavelength (e.g., 300 GHz to 430 THz). Other wavelengths are within the scope of this disclosure.
  • an EMI and noise-immune communication network may also be achieved with other physical layers, such as visible light communication (VLC), free space optics (FSO), other fields of optical wireless communication (OWC) or the like.
  • VLC visible light communication
  • FSO free space optics
  • OWC optical wireless communication
  • FIGS. 17A, 17B, 17C, and 17D are images illustrating an example battery pack controller 702.
  • FIG. 17A shows a first view of battery pack controller 702.
  • FIG. 17B shows a second view of battery pack controller 702.
  • FIG. 17C shows a third view of battery pack controller 702 with the rear cover detached.
  • FIG. 17D shows a fourth view of battery pack controller 702 with the rear cover detached.
  • the functions and structure of a battery pack controller 702 are described above, for example with respect to battery pack controller 1201 of FIGS. 12 and 13.
  • FIG. 18 is an image of a battery pack.
  • the battery cell communication system includes a battery pack controller 1101 coupled to battery group controllers 1110 via connectors 1130.
  • a battery pack controller 1101 and battery group controllers 1110 are connected in a daisy-chain topology such that each battery group controller controls a pair of boards each controlling a battery group, and sharing a single microprocessor and communication hub.
  • other topologies are within the scope of this disclosure. With the layout described above having a microprocessor sitting across two boards, the voltage difference may be substantial and the communication system utilizes an EMI and noise-immune channel, such as optical fiber, to avoid signal distortion.

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Abstract

A battery pack communication system and control system, and applications thereof. In an embodiment, a battery pack communication system permits communication within a battery energy storage system. The battery pack communication system avoids negative effects of electromagnetic interference (EMI). The battery pack communication system may include a battery pack controller and a plurality of battery groups. Each battery group may include a plurality of battery cells. A battery group controller may be mounted on one or more battery groups and communicate with the battery pack controller to monitor the battery groups. A battery group controller may include a communication hub for transmitting and receiving signals to and from the battery pack controller without EMI, for example using optical communication. The battery pack controller may operate the battery group to control the state-of-charge of the cells.

Description

NOISE-IMMUNE BATTERY PACK COMMUNICATION SYSTEM AND
APPLICATIONS THEREOF
FIELD
[0001] Embodiments disclosed herein generally relate to electrical energy storage. More specifically, they relate to a battery cell communication system that may include elements to immunize the system from electromagnetic and other interference.
BACKGROUND
[0002] Electrical energy is vital to modern national economies. Increasing electrical energy demand and a trend towards increasing the use of renewable energy assets to generate electricity, however, are creating pressures on aging electrical infrastructures that have made them more vulnerable to failure, particularly during peak demand periods. In some regions, the increase in demand is such that periods of peak demand are dangerously close to exceeding the maximum supply levels that the electrical power industry can generate and transmit.
[0003] Electrical energy storage systems store energy from the grid and supply energy to the grid, for example, to help utilities shift peak loads and perform load leveling. These systems also perform ancillary services for the grid such as, for example, frequency regulation and voltage regulation. However, to perform these functions, electrical energy storage systems must be reliable and stable. Electromagnetic interference (EMI) is a common type of noise that occurs in energy storage systems and can reduce the reliability and/or stability of these systems. Switching noise from power converters is also another source of noise in energy storage systems that can reduce their reliability and/or stability.
SUMMARY
[0004] Provided herein are system, apparatus, article of manufacture, method, and/or computer program product embodiments, and/or combinations and sub-combinations thereof, for providing a battery cell communication system for use in a battery electrical energy storage system (BESS), and components and applications thereof. In the detailed description herein, references to“one embodiment,”“an embodiment,”“an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
[0005] The present disclosure provides a battery cell communication system, and
applications thereof. In an embodiment, the electrical energy storage unit includes a battery pack controller and battery groups. Each battery group has battery cells and a battery group controller to monitor the cells. Battery cells comprise individual batteries. For example, battery cells of the present invention may include (but are not limited to) lithium-ion batteries. Each battery group controller may include charging terminals and resistors that are used to charge or discharge, respectively, energy stored in the battery cells of the respective battery group.
[0006] In an embodiment, the battery group controller monitors information about the battery group to which the battery group controller is coupled. The battery group controller may include a communication hub comprising a communication source, coupled to a microprocessor, that transmits the information about the battery group coupled to the battery group controller. The battery pack controller includes a processing unit and a battery pack communication controller. The battery pack controller may control the state-of-charge of the battery cells.
[0007] In an embodiment, a battery group controller is optically isolated by a
communication hub comprising a communication source, coupled to a microprocessor, that transmits information about the battery group coupled to the battery group controller, and utilizing a physical layer of a communications network that is immune to noise, such as electromagnetic interference and power converter switching noise.
[0008] In an embodiment, the communication hub of a battery group controller is coupled to the battery pack controller as a component of an optical fiber communication network that provides a channel to communicate data in the form of light from the battery pack controller to the battery group controller.
[0009] In an embodiment, a battery pack communication controller includes an optical fiber connector configured to communicate with at least two battery group controllers. The battery pack communication controller may send signals to battery group controllers for processing.
[0010] Further embodiments, features, and advantages of the invention, as well as the structure and operation of various embodiments of the invention, are described in detail below with reference to the accompanying drawings. In some embodiments, a battery group may refer to a plurality of battery cells. A non-limiting example of a battery group includes 4 battery cells. In some embodiments, a battery pack may refer to a plurality of battery groups, which are connected in a network. A non-limiting example of a battery pack includes 12 to 16 battery groups.
[0011] The terms“microprocessor” or“processor” as used herein may refer to, be
embodied by or otherwise included within a machine, such as a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed and programmed to perform or cause the performance of the functions described herein. A general-purpose processor or microprocessor, can alternatively be a microcontroller, or state machine, combinations of the same, or the like. A
microprocessor can also be implemented as a combination of computing devices.
[0012] Further embodiments, features, and advantages of the invention, as well as the structure and operation of the various embodiments, are described in detail below with reference to accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate the present disclosure and, together with the description, further serve to explain the principles of the disclosure and to enable a person skilled in the relevant art to make and use the disclosure.
[0014] FIGS. 1 A and 1B are diagrams illustrating an example BESS coupled to a bi directional power converter.
[0015] FIGS. 2A and 2B are diagrams illustrating an example BESS.
[0016] FIGS. 3A, 3B, and 3C are diagrams illustrating an example BESS housed in a modified shipping container. [0017] FIGS. 4A, 4B, 4C, and 4D are diagrams illustrating an example modular, stackable BESS.
[0018] FIGS. 5A, 5B, 5C, 5D, and 5E are diagrams illustrating an example modular, stackable battery stack.
[0019] FIG. 6 is a diagram illustrating air flow in an example BESS.
[0020] FIGS. 7A, 7B, 7C, 7D, 7E, and 7F are diagrams illustrating an example modular, stackable battery pack or battery unit.
[0021] FIGS. 8A, 8B, and 8C are diagrams showing an example modular, stackable
battery pack or battery unit.
[0022] FIGS. 9A, 9B, and 9C are diagrams showing an example battery assembly for a modular, stackable battery pack.
[0023] FIGS. 10A and 10B are diagrams showing an example battery stack controller.
[0024] FIG. 11 is a diagram illustrating an example battery pack communication system.
[0025] FIG. 12 is a diagram illustrating an example battery pack communication system.
[0026] FIG. 13 is a diagram illustrating an example optically isolated battery group
controller in a battery pack communication system.
[0027] FIGS. 14 and 15 are diagrams illustrating exemplary connectors in a battery pack communication system.
[0028] FIGS. 16A and 16B are diagrams illustrating a communication hub and a
communication connection coupler of a battery pack communication system.
[0029] FIGS. 17A, 17B, 17C, and 17D are images illustrating an example battery pack controller.
[0030] FIG. 18 is an image illustrating an example battery pack communication system.
DETAILED DESCRIPTION
Overview
[0031] Many renewable energy sources are prone to intermittency. Wind and solar energy technologies only produce energy when the wind is blowing or the sun is shining. In addition, remote and underserved communities may lack infrastructure such as a conventional power grid. Energy storage systems may provide a source of electrical energy in isolated electrical networks. To do so, an energy storage system must be reliable and safe. As capacity of energy storage systems increases, such systems may confront scaling difficulties due to issues such as increasing energy fields, complicated control and communications requirements and the like.
[0032] In accordance with this disclosure, an energy storage system may include inverters capable of both charging a battery group and discharging the battery group using commands issued, for example, via a computer over a network (e.g. the Internet, an Ethernet, et cetera) as described in more detail below. Also, in some embodiments, inverters can be operated as a backup power source when grid power is not available and/or electrical energy storage unit is disconnected from the grid.
[0033] Therefore, connecting or disconnecting an energy storage system to a power
source (e.g. a DC source, a solar panel or a battery), can have very different inrush current, or surge, effects on capacitors within the inverter circuitry. A large enough surge may potentially destroy the capacitors and create a fire in the inverter. Thus, inverters are particularly vulnerable. The risks of damage caused by electromagnetic interference is especially a concern in energy storage systems. Batteries, unlike solar panels for example, have low impedance. Therefore, a short circuit in a battery may create a very large current, potentially measuring in the range of several thousands of amps. Such current is substantially greater than the current in a similar size solar panel, which has a higher internal impedance.
[0034] Also unlike solar panels, batteries in an energy storage system require a
communication network to carry instructions to charge or discharge the batteries. Large currents in an energy storage system create a challenge in that noise, such as
electromagnetic interference, affects the communications of such systems. Filters may not effectively address noise in energy storage systems with large current. Also, power and frequency standards vary country -by-country. As a result, the necessary inverters vary and the cost of designing filters increases. Likewise, isolation transformers increase the cost and space requirements of an energy storage system.
[0035] The systems and methods disclosed herein provide an EMI and noise-immune battery pack communication system to minimize problems caused by electromagnetic and other interference. The battery pack communication system avoids reliance on electrical conductors prone to EMI for carrying instructions and/or information. As a result, a battery pack communication system can integrate freely with any type of electrical inverter and operate even in the absence of filters or isolation transformers. [0036] In an electrical energy storage and control unit, a battery group controller monitors and controls a subset of the battery cells that form one or more battery groups.
In an embodiment, the battery group controllers are networked and operate together as part of a communication network of battery group controllers. As discussed in more detail below, a battery pack may include a network of battery group controllers that control the battery cells included in the battery pack. A plurality of battery packs may be linked together to form a battery energy storage system, such as a multi -megawatt-hour centralized battery energy storage system.
[0037] In an embodiment, one or more of the networked battery group controllers can operate to control battery charge and discharge operations by sending commands that operate one or more inverters and/or chargers connected to the battery groups. The commands to operate inverters and/or chargers are communicated to a battery pack controller via an optical connector, such as optical fiber or the like.
[0038] In an embodiment, each battery group controller may be coupled to or may
include a communication hub. The communication hub provides a communication path or channel for an optical signal to communicate commands and information between the one or more networked battery group controllers and a battery pack controller.
A. Example Battery Energy Storage Systems
[0039] A battery pack communication system may be included in a stackable battery pack included in a battery energy storage system (BESS). Exemplary illustrations of BESS housings and applications are described below. A plurality of battery packs may be stacked one on top of the other, forming a battery stack.
[0040] FIGS. 1 A and 1B are diagrams illustrating an example BESS 100 coupled to a bi- directional power converter 102. In an embodiment, BESS 100 may include two external HVAC units l04a and l04b. In an embodiment, bi-directional power converter 102 may be capable of both charging and discharging the plurality of battery packs residing in BESS 100 using commands issued, for example, via a computer over a network (e.g. the Internet, an Ethernet, etc.), such as by an operator at an energy monitoring station.
[0041] FIG. 1B is a more detailed view of BESS 100. As shown in FIG. 1B, in an
embodiment, BESS 100 may have several doors 106 that may be opened to gain access to battery stacks 108. Battery stacks 108 may be installed inside BESS 100 and removed from BESS 100 using a forklift vehicle (not shown). This enables each battery stack 108 to be assembled external to BESS 100 and transported and installed as a single unit.
[0042] FIGS. 2A and 2B are diagrams further illustrating BESS 100 according to an
embodiment. FIG. 2 A illustrates a rear view of BESS 100 with doors 106 closed, and FIG. 2B illustrates a rear view of BESS 100 with doors 106 open.
[0043] FIGS. 3A, 3B, and 3C are diagrams illustrating another view of BESS 100 with its roof removed and doors 106 open. BESS 700 is shown with several battery stacks 108 installed. In an embodiment, BESS 100 also may include switchgear 110, which is located at one end of BESS 100.
[0044] FIG. 3B illustrates a more detailed view of switchgear 110, according to an
embodiment. FIG. 3C illustrates another view of BESS 100 including switchgear 110 located at one end of BESS 100, according to an embodiment.
[0045] FIGS. 4A, 4B, 4C, and 4D are diagrams illustrating various example modular, stackable BESS systems according to embodiments. FIG. 4A illustrates a BESS 400 having fifteen battery stacks 108, an AC switchgear unit 402, and a DC switchgear unit 404. In an embodiment, each battery stack 108 may be assembled externally and installed as a single unit into BESS 400.
[0046] FIG. 4B illustrates a BESS 420 having nine battery stacks 108, an AC switchgear unit 402, and a DC switchgear unit 404. FIG. 4C illustrates a BESS 120 having five battery stacks 108, an AC switchgear unit 402, and a DC switchgear unit 404. FIG. 4D illustrates a BESS 430 having seven battery stacks 108, an AC switchgear unit 402, and a DC switchgear unit 404.
[0047] FIGS. 5A, 5B, 5C, 5D, and 5E are diagrams illustrating a modular, stackable
battery stack 108, according to embodiments. Battery stack 108 has a battery stack controller 502 and seventeen battery packs 504. Plexiglass shields 506 protect the faces of battery stack controller 502 and the battery packs 504. Battery stack 108 has a base 508 that enables battery stack 108 to be lifted and moved using a forklift vehicle (not shown) or similar equipment. FIG. 5B illustrates another view of a battery stack 108 with plexiglass shields 506 removed, according to an embodiment.
[0048] FIG. 5C is an exploded view of a battery stack 520, according to an embodiment.
As shown in FIG. 5C, battery stack 520 may have a battery stack controller 502, nine battery packs 504, and a battery stack base 508. FIG. 5D is another exploded view of battery stack 520 that further illustrates battery stack base 508, according to an embodiment. FIG. 5E is a view of battery stack 108 that further illustrates battery stack base 508, according to an embodiment.
[0049] FIG. 6 illustrates another front view of an example BESS 600 and depicts air flow in BESS 600. The BESS 600 of FIG. 6 includes a plurality of battery packs, as described in detail below (but is not limited thereto). Fans in the ceiling panels of BESS 600 blow hot air from hot air region 610 above the ceiling toward the floor of BESS 600. An A/C unit at the back of BESS 600 draws the hot air out of BESS 600 and provides cool air to the interior of BESS 600, creating cool air region 620. The cool air regulates the temperature of the battery packs housed in BESS 600, and raises to hot air region 610 as it cools the battery packs.
[0050] FIGS. 7A, 7B, 7C, 7D, 7E, and 7F are diagrams illustrating a modular, stackable battery pack 504 (also referred to herein as a battery unit), according to embodiments. Battery pack 504 may function similarly to and include similar structure as battery pack controller 1201 of FIG. 12, as discussed in detail below.
[0051] FIG. 7A shows battery pack 504 with the plexiglass shield 506 installed. FIG. 7B shows battery pack 504 with the plexiglass shield 506 removed. As can be seen in FIG. 7B, battery pack 504 has a battery pack control unit 702. The functions and structure of a battery pack control unit 702 or battery pack controller are described above.
[0052] FIG. 7C illustrates another view of battery pack 504 with the top removed. FIG.
7D illustrates a view of battery pack 504 with the housing removed in order to better see the battery cells 704 used in battery pack 504. FIG. 7E illustrates a view of battery pack 504 with battery pack control unit 702 removed. As shown in FIG. 7E, battery pack 504 may include two battery assemblies 7l0a and 710b. Finally, FIG. 7F illustrates another view of a battery assembly 710.
[0053] FIGS. 8A, 8B, and 8C are diagrams further illustrating modular, stackable battery pack 504, according to embodiments. FIG. 8A shows battery pack 504 with plexiglass shield 506 installed.
[0054] FIG. 8B is an exploded view of battery pack 504 showing plexiglass shield 506, battery pack control unit 702, and battery assemblies 7l0a and 7l0b. These components of battery pack 504 may be housed in a battery pack housing 802. FIG. 8C is another exploded view of battery pack 504 showing plexiglass shield 506, battery pack control unit 702, and battery assemblies 7l0a and 7l0b.
[0055] FIGS. 9A, 9B, and 9C are diagrams further illustrating a battery assembly 710 for a modular, stackable battery pack 504, according to embodiments. As shown in FIG. 9A, battery assembly 710 includes battery cells 704, battery group control units 902, and bus bars 904. Each battery group control unit 902 may monitor and control two groups of battery cells, wherein each group of battery cells comprises one or more battery cells 704 connected in parallel. The functions and structure of a battery group control unit 902 (also referred to as a battery group controller) are described in more detail in embodiments below.
[0056] FIG. 9B is an exploded view of a battery assembly 710. In an embodiment, each battery assembly 710 has four battery group control units 902. FIG. 9C is a more detailed view of a battery group control unit 902. Battery group control unit 902 may function similarly to and include similar structure as battery group controllers described in detail below.
[0057] FIGS. 10A and 10B are diagrams illustrating an example battery stack controller
502, according to embodiments. In FIG. 10A, battery stack controller 502 is shown with plexiglass shield 506 installed. FIG. 10B is an exploded view of battery stack controller 502.
B. Battery Pack Communication System
[0058] FIG. 11 is a diagram illustrating an example battery pack 1100. As shown, in an embodiment, in the battery pack communication system, battery pack 1100 includes a battery pack controller 1101 coupled to battery group controllers 1110.1 to 1110. n via connectors 1130.1 to 1130. n, respectively. Battery pack controller 1101 and battery group controllers 1110.1 to 1110. n are connected in a daisy-chain topology in this example embodiment. In this example layout, each battery group controller 1110 controls a pair of boards each controlling a battery group, and sharing a single microprocessor and communication hub.
[0059] As described in detail below, the layout of the present disclosure may include a microprocessor sitting across two boards, and the voltage difference across charge terminals of the respective boards may be substantial. Thus, the communication system described in this disclosure utilizes an EMI and noise-immune channel, such as optical fiber, to avoid signal distortion. The battery group controller layout allows other topologies, such as a star network.
[0060] FIG. 12 is a diagram that illustrates components of an example battery pack
communication system 1200. The battery pack communications system of FIG. 12 includes a battery pack controller 1201.
[0061] As shown in FIG. 12, in an embodiment, battery pack communication system
1200 may include a battery pack controller 1201 having a processing unit 1202, that includes a microprocessor, and a battery pack communication controller 1203.
[0062] The battery pack communication system 1200 may additionally include battery group controllers 1210.1 to 1210. n. Battery group controllers 1210.1 to 1210. n are connected to battery pack communication controller 1203 via connectors 1230.1 to 1230. n, respectively. For example, battery group controller 1210.1 is connected to battery pack communication controller 1203 via connector 1230.1. Connectors 1230.1 to 1230. n may be configured to permit communication in a physical layer that is unaffected by electromagnetic interference or power converter switching noise, for example. While FIG. 12 shows at least four battery group controllers, the battery pack communication system is not limited to this number of battery group controllers and may include any number of battery group controllers.
[0063] Connectors 1230 may be optical fiber, for example. An optical fiber generally may comprise glass having an outer cladding layer and an internal core made from silica or Germania, for example. Alternatively, the optical fiber may be formed of plastic. - Photons of light emitted into one end of the optical fiber are reflected through the optical fiber until reaching the other end of the optical fiber. The battery pack communication system 1200 may be implemented using either single-mode fiber or multi-mode fiber.
[0064] Battery pack communication controller 1203 may be coupled to processing unit
1202 and may include a hub or communication connector 1204 to fix or install n connectors 1230.1 to 1230. n to the battery pack communication controller 1203.
Communication connector 1204 may couple connectors 1230 to a transceiver of the battery pack communication controller to send and receive communications via the connectors. A transceiver may include a communication source, such as an LED, and a communication receiver, such as a photodiode. Thus, the transceiver may act as a transducer. [0065] Each battery group controller 1210.1 to 1210. n may be coupled to a respective battery group. Alternatively, each battery group controller 1210.1 to 1210. n may be coupled to a plurality of battery groups (such as two battery groups). Each battery group controller 1210.1 to 1210. n may include a microprocessor and various sensors, such as one or more voltage sensors for monitoring voltage levels, and/or one or more
temperature sensor for monitoring temperature data of the respective battery group (e.g., microprocessor 1326 and sensors 1327 and 1328, as illustrated in the example
embodiment of FIG. 13 described below).
[0066] Furthermore, each battery group controller 1210.1 to 1210. n may be coupled to a corresponding connector 1230.1 to 1230. n by n communication hubs 1220.1 to 1220. n, which may be mounted on or part of the respective battery group controller 1210.1 to 1210. n. Each communication hub 1220 may couple the connector to a transceiver of each respective battery group controller 1210 to permit communication signals to be transmitted and received without interference, such as EMI or power converter switching noise.
[0067] Additionally, battery group controllers 1210.1 to 1210. n may provide power to any or all of the microprocessor, sensors, or communication source by transferring stored energy from one or more battery cell of the associated battery group. Therefore, an efficient communication coupling mechanism may be provided, as described below, to efficiently couple the communication source to a communication path to reduce attenuation and minimize energy conserved by the communication source.
[0068] Battery pack controller 1201 may include or be coupled to a balancing charger, which may be a power supply, such as a DC power supply, and may provide energy to all of the battery groups in a battery pack. Example balancing chargers are described in more detail below. In an embodiment, battery pack controller 1201 may provide energy to all of the battery cells in the battery pack at the same time. Additionally, battery pack controller 1201 can, via the noise free communication channel, instruct battery group controllers 1210.1 to 1210. n to selectively discharge energy from the battery cells that are included in the one or more battery groups that they respectively control. Battery group controllers 1210.1 to 1210. n may also take measurements (e.g., voltage and temperature) of the respective one or more battery groups. The battery pack controller 1201 may operate charging and discharging components (described in detail below) to control the state-of- charge of the cells.
[0069] Battery pack controller 1201 may further include a buffer to temporarily store data and commands until such information can be processed or transmitted. Battery pack controller 1201 may utilize a serial communication protocol or the like to communicate signals to battery group controllers 1210.1 to 1210. n.
[0070] As shown, battery pack communication system 1200 includes a plurality of
battery groups and a battery group controller (e.g., battery group controller 1210) coupled to one or more battery groups. In one embodiment, which is described in more detail below, n battery group controllers (where n is greater than or equal to 2) can be coupled, for example, in a star topology.
[0071] In this and other alternative arrangements, each battery group controller may have a unique address and the battery pack controller 1201 may communicate with each of the battery group controllers 1210.1 to 1210. n by addressing one or more messages to the unique address of any desired battery group controller. The one or more messages (which include the unique address of the battery group controller) may include an instruction, for example, to remove energy from a battery module, to stop removing energy from a battery module, to measure and report the temperature of the battery module, and to measure and report the voltage of the battery module. In one embodiment, battery pack controller 1201 may obtain measurements (e.g., temperature, voltage) from each of the battery group controllers using a polling technique. Battery pack controller 1201 may calculate or receive (e.g., from a controller outside of battery cell communication system 1200) a target voltage for the battery pack, and may adjust each of the battery groups to the target voltage. Thus, battery cell communication system 1200 may be considered a smart battery pack, able to self-adjust its battery cells to a target voltage. Alternatively or additionally, each battery group may have a unique address and the battery pack controller 1201 may communicate with the battery group controller 1220 by addressing one or more messages directed to control of one or more individual battery groups.
C. Optically Isolated Battery Group Controllers
[0072] Each battery group controller 1210 of the battery pack communication system
1200 may be optically isolated in that the input and output of signals in each battery group controller is unaffected by the presence of an electric field or electrical noise. [0073] FIG. 13 is a diagram illustrating an example battery pack controller connected to a battery group controller. Battery pack controller 1301 may receive commands or information from an outside system. Battery pack controller 1301 may further include a battery pack communication controller having communication connector 1304 to transmit signals to battery group controller 1310 and to receive signals.
[0074] Battery group controller 1310 includes a microprocessor 1326 and various sensors
(e.g., 1327 and 1328) such as one or more voltage sensors and/or one or more temperature sensors. Battery group controller 1310 may further include a communication hub 1320, for example, to send and receive signals, including sensor data and commands. In accordance with the communicated information, battery pack controller 1301 may instruct one battery group to discharge. Accordingly, battery group controller 1310 may receive discharge energy through positive terminal 1312 and negative terminal 1313. Battery pack controller 1301, which may be a battery pack controller as discussed above with respect to FIG. 12 comprising a processing unit and a battery pack communication controller, may in embodiments instruct a battery group to charge or transfer energy. Upon receiving a discharge command, battery group controller 1310 may utilize a discharging element, such as shunt resistors 1315, to discharge stored energy. For example, a determination to discharge stored energy by a discharging element, such as shunt resistors 1315, based on information received from the battery pack controller 1301 via the optical fiber that couples the battery group controller 1310 to the battery pack controller 1301. That is, if a battery group is determined to be unbalanced with respect to the amount of energy stored relative to other battery groups, then battery pack controller 1301 may instruct one or several battery group controllers to commence discharging by switching on the associated shunt resistors 1315, which may occur while charge is provided to all battery groups via each respective pair of terminals 1312 and 1313.
[0075] In addition to the above-mentioned advantages, utilizing an EMI and noise- immune communication system to couple battery group controller 1310 to battery pack controller 1301 also permits an efficient battery group controller layout that would otherwise be difficult to achieve. As shown in FIG. 13, in an embodiment, battery group controller 1310 can be configured utilizing two circuit boards 1310A and 1310B, each controlling a distinct battery group with independent sensors, discharge element(s) (e.g., shunt resistors) and battery cell terminals. Boards 1310A and 1310B are integrated as a single battery group controller. The boards share a single microprocessor and communication hub 1320 in this embodiment.
[0076] FIGS. 14 and 15 are diagrams illustrating exemplary connectors in a battery pack communication system. As shown, a battery pack communication controller 1403 may be connected via an EMI and noise-immune communication channel to communication hubs (e.g., 1420.1 of FIG. 14) mounted on battery group controllers.
[0077] As shown in FIG. 14, in one embodiment a transceiver (e.g. a transducer) of
battery pack communication controller 1403 is linked to n communication hubs 1420.1 to 1420. n, each of which is mounted on or part of a battery group controller. In this embodiment, optical fiber 1430, is fixed atop optical fiber connector 1404, such that a communication source (e.g. LED) of the transceiver is positioned substantially underneath the optical fibers. In order to avoid excess light dispersion, fixing the optical fibers atop of the connector allows the connections to be coupled directly or nearly directly over the communication source. Therefore, an advantage of this configuration is that light dispersion is minimized even for a topology involving many connections to a central host (e.g., a star topology). Whereas communication hubs 1420.1 to 1420. n only need provide light intensity sufficient to reach one host (battery pack communication controller 1403), the communication source of optical fiber connector 1404 needs to generate light intensity sufficient to transmit an optical signal to the communication hub of each battery group controller. Therefore, optical fibers 1430 are fixed over the communication source to minimize light dispersion.
[0078] In fixing optical fibers 1430 to the top of optical fiber connector 1404 (or to the top of communication hubs 1420.1 to 1420. n), there may be a problem of the fibers inadvertently being crushed by a human interaction or by an object placed over the battery pack communication controller. As shown in FIG. 15, in another embodiment, optical fibers may be inserted through the sides of optical fiber connector 1504 and through the sides of communication hubs 1520.1 to l520.n. Optical fiber connector 1504 may be cylindrically shaped, in this embodiment, to reduce and equalize the optical path between a communication source of battery pack communication controller 1503 and each optical fiber 1530. Alternatively, optical fiber connector 1504 may also be implemented as a half or semi-cylindrical shape or the like or any other shape. [0079] Optical fiber provides another advantage in that it is easy to fix to the communication hub, e.g., by press-fit or by adhesive. In the present invention, a tapered hole or cavity may be provided, for example, for each optical fiber within the casing of optical fiber connector 1404 of FIG. 14 or 1504 of FIG. 15. A tapered hole or cavity may also be provided, for example, in communication hubs 1520.1 to l520.n. Additionally or alternatively, optical fibers may be fixed by an adhesive or the like. Optical fibers do not suffer from, for example, metal corrosion or solder joint failures. Therefore, in addition to inoculating the battery cell communication system from electromagnetic interference and power converter switching noise, the configuration as described above may provide an advantage in reducing connectivity issues.
[0080] As described above, a battery pack communication system may be configured in a star topology (e.g., spoke and hub). However, other arrangements can be achieved without undue experimentation. For example, the system may alternatively be arranged in a daisy-chained topology, if a sufficiently intense light source is provided in battery pack communication controller 1403 and/or optical fiber having sufficiently low attenuation. A daisy chain arrangement may allow optical fiber connector 1404 of FIG. 14 or 1504 of FIG. 15 and associated optical fiber (1430 of FIG. 14 or 1530 of FIG. 15) to be simplified to provide a single optical fiber port.
[0081] In an embodiment, the transceiver of battery pack communication controller 1403 may be a chip mounted to the surface of the controller. Alternatively, the transceiver may be integrated with the battery pack communication controller 1403 as a printed circuit board or other component of the battery pack communication controller 1403.
Additionally or alternatively, some components of the transceiver may be integrated with the battery pack communication controller while other components of the transceiver may constitute a separate printed circuit board that attaches to the battery pack communication controller. Also, processing unit 1202 and battery pack communication controller 1203 are shown as separate elements of battery pack controller 1201, e.g., in FIG. 12.
However, these elements may also be integrated together, for example, in a single printed circuit board.
[0082] There is no specific constraint on the length or other dimension of the optical fibers (i.e., optical fiber 1430 of FIG. 14 or 1530 of FIG. 15). However, the dimensions should be suitable to allow a sufficient light intensity to reach a target controller for proper communications.
D. Communication Hub for a Battery Group Controller
[0083] FIGS. 16A and 16B are diagrams illustrating a cross section of an example
communication hub 1620 of a battery pack communication system. Efficient and functional optical networks modulate light to reach the receiver with enough power to be demodulated correctly. Improper connectors and optical components may cause a reduction in optical power of the transmitted signal, i.e., attenuation. The communication hub described herein provides a path for optical signals with sufficient light intensity to ensure proper communications. The communication hubs described with respect to FIG. 14 and FIG. 15 may be implemented as discussed with respect to FIG. 16A and 16B.
[0084] As shown in FIG. 16 A, the communication hub 1620 may include an optical fiber coupler housing 1621 and an optical fiber coupler reflector 1622. Each of the optical fiber coupler housing 1621 and the optical fiber coupler reflector 1622 may comprise, for example, plastic. The housing and reflector couple light from optical fiber 1630 to transceiver 1611, providing a communication channel for an optical signal to be transmitted and received by the transceiver via the optical fiber. In an embodiment, optical fiber coupler housing 1621 and the optical fiber coupler reflector 1622 may be formed as a single component. A reflective coating may be applied to the component to couple light between the optical fiber and transceiver 1611.
[0085] Transceiver 1611 may transform an optical signal into an electrical signal, and provide a resulting electrical signal to a microprocessor of battery group controller 1610. Likewise, transceiver 1611 may transform an electrical signal of battery group controller 1610 into an optical signal, and transmit the optical signal via the communication hub. Thus, transceiver 1611 may include a communication source, such as an LED, and a light receiver, such as a photodiode. Thus, the transceiver may act as a transducer.
[0086] Communication hub 1620 provides optical fiber coupler housing 1621 that is fixed to battery group controller 1610 by at least fixing mechanism 1623. As shown, fixing mechanism 1623 may be a snap or push-in rivet that fixes optical fiber coupler housing 1621 to battery group controller 1610. Alternatively, optical fiber coupler housing 1621 may be joined through any of a variety of mechanical fasteners, including at least one of a bolt, a screw, an adhesive, an interference fit, press-fit, etc. [0087] FIG. 16B is a diagram further illustrating an example optical coupler of a battery pack communication system. As shown in 16B, optical fiber coupler housing 1621, for example, has a void 1625 that may be fitted to transceiver 1611. When optical fiber coupler housing 1621 is fixed to battery group controller 1610, transceiver 1611 is securely coupled within the void of optical fiber coupler housing 1621. Optical fiber coupler housing 1621 also may include a cavity 1624 in which an optical fiber 1630 can be coupled. Optical fiber 1630 may be secured in cavity 1624 by press-fit, adhesive, and the like. As shown, cavity 1624 may optionally be tapered to enable the optical fiber to be secured by press-fit. Alternatively, the optical fiber may be formed integrally with the optical fiber coupler housing 1621.
[0088] Optical fiber coupler reflector 1622 may include a reflective surface facing void 1625 and cavity 1624. The reflector is provided at an angle such that incident light may be reflected from the optical fiber 1630 joined with cavity 1624 in a direction toward void 1625 and vice versa. An optical signal is communicated to and from battery pack controller 1601 by optical fiber 1630. Optical fiber coupler reflector 1622 is illustrated as a component separate from optical fiber coupler housing 1621. The reflector and the housing may be securely fastened together to avoid vibration and/or light attenuation. For example, the optical fiber coupler reflector 1622 may be mounted on the slanted surfaces of optical fiber coupler housing 1621 by an adhesive or the like. The components are provided separately to facilitate mounting and dismounting. Alternatively, the optical fiber coupler housing 1621 and the optical fiber coupler reflector 1622 may be fabricated integrally as a single component.
[0089] In some embodiments, the transceiver 1611 may be integrated with the battery group controller 1610 either as an integrated printed circuit board, or as a component of the battery group controller 1610. Additionally or alternatively, some components of the transceiver 1611 may be integrated with the battery group controller 1610 while other components of the transceiver 1611 may constitute a separate printed circuit board that attaches to the battery group controller 1610.
[0090] The battery group controller 1610 includes a microprocessor capable of
communicating with the transceiver 1611. Additionally, in an embodiment, a post- amplifier may be coupled to the transceiver 111 and/or to battery group controller 1610 to amplify the optical signal and provide an amplified signal to the battery group controller 110
[0091] An optical signal may be modulated and demodulated by transceiver 1611, e.g., converted into digital bits. For example, light directed to transceiver 1611 may be interpreted as a 1 whereas an absence of light may be interpreted as a 0. Thus, utilizing the communication hub of the battery pack communication system, an optical signal may contain information in a syntax similar to that of a corresponding electrical signal, but for the physical layer. The optical signal may be in the form of light in a visible wavelength range (e.g., 430 to 770 THz). Additionally or alternatively, the signal may include light in the infrared wavelength (e.g., 300 GHz to 430 THz). Other wavelengths are within the scope of this disclosure.
[0092] Furthermore, while embodiments described herein indicate the use of a specific physical layer, such as optical fiber, an EMI and noise-immune communication network may also be achieved with other physical layers, such as visible light communication (VLC), free space optics (FSO), other fields of optical wireless communication (OWC) or the like.
[0093] FIGS. 17A, 17B, 17C, and 17D are images illustrating an example battery pack controller 702. FIG. 17A shows a first view of battery pack controller 702. FIG. 17B shows a second view of battery pack controller 702. FIG. 17C shows a third view of battery pack controller 702 with the rear cover detached. FIG. 17D shows a fourth view of battery pack controller 702 with the rear cover detached. The functions and structure of a battery pack controller 702 are described above, for example with respect to battery pack controller 1201 of FIGS. 12 and 13.
[0094] FIG. 18 is an image of a battery pack. As shown in the photograph, the battery cell communication system includes a battery pack controller 1101 coupled to battery group controllers 1110 via connectors 1130. As in FIG. 11 above, a battery pack controller 1101 and battery group controllers 1110 are connected in a daisy-chain topology such that each battery group controller controls a pair of boards each controlling a battery group, and sharing a single microprocessor and communication hub. As described above, other topologies are within the scope of this disclosure. With the layout described above having a microprocessor sitting across two boards, the voltage difference may be substantial and the communication system utilizes an EMI and noise-immune channel, such as optical fiber, to avoid signal distortion.
[0095] The foregoing description of specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.

Claims

WHAT IS CLAIMED IS:
1. A battery communication system for a battery pack, comprising:
a plurality of battery groups;
a plurality of battery group controllers, each battery group controller configured to control at least one battery group,
a battery pack controller comprising a battery pack communication controller, wherein the battery pack communication controller is coupled to each of the plurality of battery group controllers;
wherein each of the battery group controllers, comprises:
a microprocessor,
a sensor, coupled to the microprocessor, configured to gather data about one or more battery groups to which the battery group controller is coupled, and
a communication hub comprising a communication source, coupled to the microprocessor, configured to transmit the data about the one or more battery groups to which the battery group controller is coupled to the battery pack communication controller.
2. The battery communication system of claim 1, wherein the battery pack communication controller is coupled to each of the plurality of battery group controllers via an optical fiber.
3. The battery communication system of claim 1, wherein each battery group controller is configured to control two battery groups.
4. The battery communication system of claim 1, wherein the communication source is a light source.
5. The battery communication system of claim 1, wherein each of the plurality of battery group controllers further comprises:
an optical fiber connector to couple light from the light source to an optical fiber.
6. The battery communication system of claim 5, wherein the optical fiber connector comprises a cavity in which the optical fiber is inserted.
7. The battery communication system of claim 5, wherein the optical fiber connector is press-fit into the cavity.
8. The battery communication system of claim 5, wherein one of the optical fiber and the optical fiber connector is made of plastic.
9. The battery communication system of claim 5, further comprising:
a second optical fiber connector configured to couple the optical fiber to a transceiver of the battery pack communication controller.
10. The battery communication system of claim 9, wherein the second optical fiber connector has a plurality of cavities, and each of these plurality of cavities couples a different optical fiber to the transceiver.
11. The battery communication system of claim 1, wherein the light source is a light emitting diode.
12. The battery communication system of claim 1, wherein each of the plurality of battery group controllers, further comprises:
an energy discharging element configured to discharge the battery group to which the battery group controller is coupled, and
wherein the energy discharging element discharges the battery group based on information received from the battery pack controller via an optical fiber coupled to the battery group controller.
13. The battery communication system of claim 1, wherein the sensor gathers one of cell voltage data and cell temperature data.
14. The battery communication system of claim 1, wherein one of the microprocessor, the sensor, and the light source is powered from the battery group to which the battery group controller is coupled.
15. The battery communication system of claim 1, wherein each battery group comprises a plurality of lithium ion battery cell.
16. A battery communication system for a battery pack, comprising:
a battery pack communication controller; and
a battery group controller mounted on one or more battery groups and coupled to the battery pack communication controller via an optical fiber,
wherein the battery group controller comprises:
a microprocessor,
a sensor, coupled to the microprocessor, configured to gather data about the battery group,
a light source, coupled to the microprocessor, configured to transmit the data about the battery group to the battery pack communication controller, and
an energy discharging element configured to discharge energy from a battery group based on an instruction from the battery pack communication controller.
17. The battery communication system of claim 16, wherein the battery group controller, further comprises:
an optical fiber connector to couple light from the light source to the optical fiber.
18. The battery communication system of claim 17, further comprising:
a second optical fiber connector to couple the optical fiber to a transceiver of the battery pack communication controller.
19. The battery communication system of claim 17, wherein the optical fiber connector has a cavity in which the optical fiber is inserted.
20. The battery communication system of claim 19, wherein the optical fiber connector is press-fit into the cavity.
21. The battery communication system of claim 17, wherein at least one of the optical fiber and the optical fiber connector is made of plastic.
22. The battery communication system of claim 16, wherein the sensor gathers at least one of cell voltage data and cell temperature data.
23. The battery communication system of claim 16, wherein at least one of the
microprocessor, the sensor, and the light source is powered from the battery cell.
PCT/US2019/035822 2018-06-08 2019-06-06 Noise-immune battery pack communication system and applications thereof WO2019236869A1 (en)

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