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US20060012334A1 - Automated battery cell shunt bypass - Google Patents

Automated battery cell shunt bypass Download PDF

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Publication number
US20060012334A1
US20060012334A1 US11/131,930 US13193005A US2006012334A1 US 20060012334 A1 US20060012334 A1 US 20060012334A1 US 13193005 A US13193005 A US 13193005A US 2006012334 A1 US2006012334 A1 US 2006012334A1
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US
United States
Prior art keywords
battery cell
cell
shorting
internal
shorting bar
Prior art date
Legal status (The legal status 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 status listed.)
Abandoned
Application number
US11/131,930
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English (en)
Inventor
John Watson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Railpower LLC
Original Assignee
RailPower Technologies Corp
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 RailPower Technologies Corp filed Critical RailPower Technologies Corp
Priority to US11/131,930 priority Critical patent/US20060012334A1/en
Assigned to RAILPOWER TECHNOLOGIES CORP. reassignment RAILPOWER TECHNOLOGIES CORP. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: WATSON, JOHN DAVID
Publication of US20060012334A1 publication Critical patent/US20060012334A1/en
Assigned to RAILPOWER, LLC reassignment RAILPOWER, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: RAILPOWER HYBRID TECHNOLOGIES CORP., RAILPOWER TECHNOLOGIES CORP.
Abandoned legal-status Critical Current

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    • B60L3/0046—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to electric energy storage systems, e.g. batteries or capacitors
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Definitions

  • the present invention relates generally to a method for automatically electrically removing individual battery cells which are malfunctioning from a battery pack of cells electrically connected in series.
  • Batteries in particular large lead-acid batteries, are typically fabricated first by arranging a series of positive and negative plates separated by a separator material in a stack. Positive and negative bus bars are typically welded to positive and negative tabs that extend from the tops of the positive and negative plates respectively.
  • the positive and negative terminals of the battery are typically fabricated as part of the bus bar assembly.
  • the separator material is impregnated with an appropriate electrolyte and the top of the battery case is installed. Atypical cell is illustrated in FIG. 1 , which is well-known prior art.
  • degraded or failed plate pairs in a malfunctioning cell can be open-circuited by utilizing a fuse mechanism to remove one of more electrode pairs in the affected cell from service.
  • the open-circuit approach typically applies to electrode pairs that are in parallel in a cell. This leaves a smaller number of plate pairs in the cell. This is particularly effective if the failing electrode pair has a soft short and is draining the other electrode pairs in the cell. The short causes local heating which makes the electrode hotter and a thermal fuse opens-circuits the failing electrode pair.
  • the disadvantage of this approach is the additional cost and complexity of having a fuse mechanism on each plate pair, and a reduction in the maximum current available from the battery pack since all cells must be derated to the performance parameters of the cell with the shorted plate pair or pairs. This approach can also cause in imbalance in the state-of-charge (“SOC”) between cells which can lead to loss of cell lifetimes.
  • SOC state-of-charge
  • Another approach is to use a battery management system where the battery pack performance is reduced to the level of the degraded or failing cell. This approach limits the maximum available pack current as well as the available storage capacity and output voltage of the pack to match the capability of the malfunctioning cell.
  • a third approach is to short-circuit a malfunctioning cell to eliminate the cell from the battery pack by shunting pack current around the malfunctioning cell.
  • This approach has the advantage of not reducing the maximum available battery pack current. In a large battery pack which may be comprised of several hundred cells in series, there will be a small reduction in battery pack voltage and ampere-hour capacity when one or a few cells are bypassed.
  • a battery pack that includes:
  • the selected event is commonly at least one of the following:
  • the present invention can reduce the risk of battery fires, increase the effective lifetime of the battery pack, and provide a higher effective battery pack energy output over time.
  • the shorting mechanism commonly does not reduce the maximum battery peak current.
  • the shorting mechanism includes a piston having a position that changes in response to the internal pressure, a shorting bar, and a shorting bar deployment member.
  • the position of the piston causes the shorting bar deployment member to position the shorting bar in contact with positive and negative bus bars of the selected battery cell, thereby shorting out the cell and forming a shunt bypass of the selected battery cell.
  • the shorting mechanism includes a thermally expansive material having a length that increases in direct response to the internal temperature, a shorting bar, and a shorting bar deployment member.
  • the length of the thermally expansive material causes the shorting bar deployment member to position the shorting bar in contact with positive and negative bus bars of the selected battery cell, thereby shorting out the cell and forming a shunt bypass of the selected battery cell.
  • the shorting mechanism includes a shorting bar, a sensor that senses the occurrence of a selected event, a controller in communication with the sensor, and a shorting bar deployment member.
  • the controller determines from sensor input that the selected event has occurred, the controller causes the shorting bar deployment member to position the shorting bar in contact with positive and negative bus bars of the selected battery cell, thereby shorting out the cell and forming a shunt bypass of the selected battery cell.
  • the first and second configurations are particularly desirable. They can be low cost, robust, are self-actuating and have a high degree of reliability.
  • a “battery cell” or “cell” is an individual sealed or vented cell comprised of one or more internal plate assemblies, each plate assembly comprised of a negative plate, a separator material and a positive plate.
  • the battery cell may have one or more external negative and positive terminals.
  • a “plate pair” is the basic unit of a cell and is comprised of a negative plate, a separator material and a positive plate.
  • a voltage typical of the particular battery chemistry is developed between the positive and negative plates. In a lead-acid battery, this voltage is typically about 2.13 volts at full charge.
  • a “battery rack” is a mechanical structure in which battery cells are mounted.
  • a “battery module” is a collection of cells mounted in a battery rack frame assembly of convenient size.
  • a “battery pack” is an assembly of many individual battery cells connected electrically.
  • the assembly may be comprised of subassemblies or modules comprised of individual battery cells.
  • the battery pack usually, but not always, has one overall positive and negative terminals for charging and discharging the cells in the pack.
  • a “bus bar” refers to an electrical conductivity path involving a negative or positive polarity of a plurality of plates in one or more battery cells.
  • a bus bar may interconnect a number of battery terminals in one or more battery cells or may be a single battery terminal of only one battery cell.
  • “Float service” as applied to a battery means operating the battery under rigid voltage conditions to overcome self-discharge reactions while minimizing overcharge and corrosion of the cell's positive grid.
  • “Cyclical service” as applied to a battery cell means operating the battery by alternating discharging the cell to a significantly lower capacity or state-of-charge and then recharging the cell to at or near its full capacity.
  • a “malfunctioning battery cell” is taken to be a cell in which there is a significant degradation of capacity or significant change in open-circuit voltage; a significant increase in internal plate resistance; and/or significant internal shorting in one or more plate pairs, any of which may cause a cell to degrade in performance or fail.
  • At least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation.
  • each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
  • FIG. 1 is an isometric cutaway view of an individual prior art battery cell
  • FIG. 2 shows a side view of two possible mechanisms for automatically shorting out battery cells
  • FIG. 3 shows a top view of a mechanism for automatically shorting out battery cells
  • FIG. 4 shows a top view of a motorized mechanism for automatically shorting out battery cells.
  • FIG. 1 shows a schematic cutaway view of a large energy storage battery cell 100 that is typical of the cells used in a large battery pack assemblies.
  • the battery case 101 contains negative plates 102 interleaved with positive plates 103 , the latter typically inserted in a pocket 104 of separator material.
  • the separator 104 is typically impregnated with electrolyte.
  • the plates 102 and 103 terminate outside the battery at a negative terminal 105 and a positive terminal 106 .
  • the example of FIG. 1 is that of a single cell where the open circuit voltage across the terminals 105 and 106 is the same as the open circuit voltage across any pair of positive and negative plate pairs.
  • batteries such as for example an automotive starter battery may be comprised of several plate pairs in series or in parallel or combinations thereof.
  • the open circuit voltage across the terminals is approximately 12 volts or 6 times the number of internal series connected plate pairs.
  • the battery cell 100 is shown with a vent 107 which allows excess gas generated for example during an equalization charge to be discharged when a predetermined internal pressure is exceeded.
  • FIG. 2 shows a side view of two possible mechanisms for automatically moving an external bus bar to cause a by-pass shunt of a battery cell.
  • the battery cell is comprised of a case 201 which contains a series 202 of positive and negative plates pairs separated by electrolyte.
  • the present invention is directed towards cells in which the internal plate pairs are electrically connected in parallel although the invention may be applied to cells in which the internal plate pairs are electrically connected in series or in combinations of series and parallel groups. It is preferable to apply the present invention to shunt a cell where the open circuit voltage is low such as for example a cell where all the plate pairs are connected electrically in parallel.
  • a first shorting mechanism 210 is based on an element 213 that is made of a material that has a large thermal expansion coefficient relative to the other components so that the element 213 becomes longer relative to the other components as the internal battery temperature increases. Thus internal battery temperature is the event that activates this shorting mechanism.
  • the element 213 may be comprised, for example, of a material with an anomalously high expansion coefficient or it may be a sealed cylinder that expands when an enclosed liquid or gas lengthens the cylinder as the enclosed liquid or gas is heated by exposure to the temperature in the cell.
  • the element 213 is fixed to a housing 212 which is in turn attached to the top of the battery case 201 .
  • the shorting bar 211 is located on the outside of the case 201 and is shown in a top view in FIG. 3 .
  • the element 213 When the element 213 expands, it forces the screw mechanism 214 to rotate a small amount which in turn rotates the shorting bar.
  • the element 213 is directly exposed to the internal temperature of the battery and when the internal temperature reaches a predetermined threshold, the shorting bar 211 is caused to rotate sufficiently to contact the positive and negative bus bars (as shown in FIG. 3 ) thereby shorting out the cell and forming a shunt by-pass. Since the cell plate pairs are electrically connected preferably in parallel, there is voltage difference between the positive and negative bus bars of typically a few volts to a few tens of volts and the amount of rotation required to short out the battery is typically between about 5 and 10 degrees.
  • a second shorting mechanism 220 is based on a piston 223 that moves in response to internal battery pressure so that the piston 223 pushes upwards as the internal battery pressure increases.
  • the piston 223 is free to move within a housing 212 which is in turn attached to the top of the battery case 201 .
  • a screw mechanism 224 which is attached to a shorting bar 221 .
  • the shorting bar 221 is located on the outside of the case 201 and is shown in a top view in FIG. 3 .
  • the piston 223 moves upward, it forces the screw mechanism 224 to rotate a small amount which in turn rotates the shorting bar 221 .
  • the piston 223 is directly exposed to the internal pressure of the battery and when the internal pressure reaches a predetermined threshold, the shorting bar 221 is caused to rotate enough to contact the positive and negative bus bars (as shown in FIG. 3 ) thereby shorting out the battery cell.
  • internal battery pressure is the event that activates this shorting mechanism.
  • the battery plate pairs are electrically connected preferably in parallel, there is voltage difference between the positive and negative bus bars of typically a few volts to a few tens of volts and the amount of rotation required to short out the battery is typically between about 5 and 10 degrees. Many batteries have vents (not shown) to relieve internal pressure that is built up by evolving gases.
  • vents used in the present invention can be throttled to allow small amounts of gas to escape slowly.
  • gas pressure builds up rapidly such as for example when the internal plate pair resistances increase substantially, the vents cannot remove gas fast enough to prevent pressure build-up.
  • the piston 223 is then exposed to enough pressure to rotate the shorting bar 221 so that it shorts out the battery cell, thereby substantially reducing the current flow across the electrode plates where the excess energy is being generated.
  • the shorting bars 211 and 221 can contain a fuse element that would disrupt the short circuit in the event the battery cell retains a substantial undetected charge.
  • FIG. 3 shows a top view of a mechanism for manually or automatically shorting out large battery cells.
  • a bus bar connects several terminals of a given polarity so as to lower the overall terminal resistance.
  • This view shows battery cell container 301 which houses three battery cells 306 , 307 and 308 .
  • Bus bar 302 forms a positive terminal and connects the positive plates of battery cell 306 .
  • Bus bar 305 connects the negative plates of battery cell 306 with the positive plates of battery cell 307 .
  • Bus bar 304 connects the negative plates of battery cell 307 with the positive plates of battery cell 308 .
  • Bus bar 303 forms a negative terminal and connects the negative plates of battery cell 306 .
  • the three battery cells are connected in series in this example.
  • Shorting bars 311 , 312 and 313 are shown and each can rotate independently about a center post such as 314 .
  • the center posts 314 are solidly attached to each shorting bar and correspond to the screw mechanisms 214 and 224 shown in FIG. 2 .
  • the shorting bar 311 is shown in contact with bus bars 302 and 305 thereby shorting out the battery cell 306 .
  • the shorting bars 312 and 313 are shown not in contact with any of the bus bars so that battery cells 307 and 308 are not shorted out. In this example therefore, two battery cells 307 and 308 are shown electrically connected in series with battery cell 306 bypassed by the shorting bar 311 .
  • the shorting bars may be rotated into contact with the main current carrying bus bars by either of the mechanisms 210 or 220 illustrated in FIG. 2 .
  • FIG. 4 shows a top view of a motorized mechanism 413 for automatically shorting out battery cells.
  • the motorized mechanism 413 is preferably mounted on the outside of the battery cell to avoid exposure to corrosive gases that typically collect in the interior of the cell.
  • This view shows two cells 401 and 402 .
  • Bus bar 403 forms a positive terminal and connects the positive plates of battery cell 401 .
  • Bus bar 404 connects the negative plates of battery cell 401 with the positive plates of battery cell 402 .
  • Bus bar 405 connects the negative plates of battery cell 402 with the positive plates of next battery cell in the series (not shown).
  • the two battery cells are connected in series in this example.
  • the negative and positive polarities can be reversed.
  • Shorting bars 411 and 415 are shown and each can rotate independently about a center post such as 412 .
  • the center posts 412 are solidly attached to each shorting bar.
  • a small motor 413 is shown connected to the center posts 412 in this example by a belt drive 414 .
  • the motor 413 may be powered by any number of electrical sources including by the power used to operate a battery monitoring system (not shown) or by power in the cell on which the motor is mounted or from one or more of the other cells in the battery pack.
  • the belt drive 414 is one of many well-known means for a motor 413 to rotate a shorting bar 411 about a center post 412 .
  • the shorting bar 415 is shown not in contact with any of the bus bars so that battery cell 402 is not shorted out.
  • a motorized mechanism may be used to engage a shorting bar with bus bars by moving the shorting bar in a linear motion until contact is made with the bus bars.
  • the motorized mechanism described above may be actuated by a sensor which detects any of a number of cell parameters such as for example an anomalously high internal cell pressure, an anomalously high internal cell temperature, an anomalously high internal cell resistance, an anomalously high cell voltage during charging and/or an anomalously low cell voltage during normal discharging, where the anomalously low cell voltage during normal discharging may be of reversed polarity from its normal polarity. Any of these may be monitored by a sensor placed on or near the cell and the sensor monitored by a controller which can activate the motorized mechanism and cause it to short out the cell.
  • a sensor which detects any of a number of cell parameters such as for example an anomalously high internal cell pressure, an anomalously high internal cell temperature, an anomalously high internal cell resistance, an anomalously high cell voltage during charging and/or an anomalously low cell voltage during normal discharging, where the anomalously low cell voltage during normal discharging may be of reversed polarity from its normal polarity. Any of these may be monitored by a sensor placed on or near the cell
  • the above inventions are directed to use in a large battery pack where all the battery cells are in series.
  • a cell or cells develop an anomalously high internal resistances or internal short or both, this can lead to reduced performance and eventually cause the battery pack to shut down.
  • a small amount of propellant can be contained within in a mechanism, that when a selected temperature is exceeded, initiates the propellant to generate gases which move a piston that in turn pushes on a screw mechanism that causes an external shorting bar to rotate a small amount to short out the cell.
  • internal battery temperature is the event that activates this shorting mechanism.
  • a small arms or rifle primer can be contained within in a mechanism, that when a selected internal cell pressure or temperature is exceeded, fires the primer to generate gas which then moves a piston that in turn pushes on a screw mechanism that causes an external shorting bar to rotate a small amount to short out the cell.
  • internal battery temperature and/or pressure is the event that activates the shorting mechanism.
  • a propellant or primer can be initiated by a controller that has sensed any of a number of selected events such as cell pressure, temperature, resistance, or voltage that is out of its normal range.
  • the shorting bar may move in a nonrotational manner.
  • the bar may move vertically in any of the above embodiments, such as about a fulcrum.
  • One end of the bar may always be in contact with the first bus bar while the other end is moved rotationally or nonrotationally into contact with the second bus bar.
  • shorting is effected by activating a switch electrically connected to the opposite polarity bus bar(s) of one or more battery cells.
  • the present invention in various embodiments, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure.
  • the present invention in various embodiments, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and ⁇ or reducing cost of implementation.

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  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Power Engineering (AREA)
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  • Mechanical Engineering (AREA)
  • Transportation (AREA)
  • Sustainable Energy (AREA)
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  • Life Sciences & Earth Sciences (AREA)
  • Automation & Control Theory (AREA)
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  • Battery Mounting, Suspending (AREA)
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