System and method for disengaging battery strings

Patent metadata

Field	Value
Publication number	US-12355277-B2
Application number	US-202117381258-A
Country	US
Kind code	B2
Filing date	Jul 21, 2021
Priority date	Jul 21, 2021
Publication date	Jul 8, 2025
Grant date	Jul 8, 2025

Abstract

A machine includes a plurality of battery string modules that supply electric current to an inverter of the machine. The machine also includes a control system that opens at one contactor coupled to at least one battery string module of the plurality of battery string modules to disconnect the at least one battery string module. The other battery string modules of the plurality of battery string modules, apart from the at least one battery string module, continue supplying electric current to the inverter of the machine while the at least one battery string module is disconnected.

First claim

The invention claimed is:

1. An all-electric battery-operated machine, comprising:
a plurality of high voltage (HV) battery string modules configured to supply electric current to an inverter of the all-electric battery-operated machine, the plurality of HV battery string modules being grouped as a plurality of pairs of the HV battery string modules, including a first pair having a first HV battery string module and a second HV battery string module and a second pair having a third HV battery string module and a fourth HV battery string module;
a plurality of pairs of high voltage (HV) contactors respectively associated with each said pair of the HV battery string modules, including a first pair of HV contactors and a second pair of HV contactors, a first HV contactor of each of the plurality of pairs of HV contactors being connected to a positive terminal of the inverter of the all-electric battery-operated machine and a second HV contactor of each of the plurality of pairs of HV contactors being connected to a negative terminal of the inverter of the all-electric battery-operated machine;
a plurality of high voltage (HV) battery string disconnects, including a first HV battery string disconnect and a second HV battery string disconnect, each of the plurality of HV battery string disconnects including one or more disconnect switches, being electrically coupled to a corresponding pair of the plurality of pairs of the HV battery string modules, and not being electrically coupled to any of the other pairs of the plurality of pairs of the HV battery string modules; and
a control system including processing circuitry configured to:
open at least one of the HV contactors of one of the plurality of pairs of HV contactors to disconnect the corresponding pair of HV battery string modules,

wherein all other pairs of HV battery string modules of the plurality of HV battery string modules, apart from the corresponding pair of HV battery string modules having been disconnected, are configured to continue supplying electric current to the inverter of the machine while the corresponding pair of HV battery string modules remain disconnected,
wherein each of the plurality of HV battery string disconnects is electrically coupled between the corresponding pair of the plurality of pairs of the HV battery string modules and electrically connected directly to the processing circuitry of the control system, including the first HV battery string disconnect being electrically coupled between the first and second HV battery string modules and the second HV battery string disconnect being electrically coupled between the third and fourth HV battery string modules, and
wherein the processing circuitry of the control system is configured to:
responsive to opening of the one or more disconnect switches of the first HV battery string disconnect, open at least one of the first HV contactor or the second HV contactor of the first pair of HV contactors to disconnect the first pair of HIV battery string modules without opening the first and second HV contactors of any other pair of HV contactors of the plurality of pairs of HV contactors.

2. The all-electric battery-operated machine of claim 1 , further comprising:
a main relay electrically coupled to the pairs of HV contactors.

3. The all-electric battery-operated machine of claim 2 , wherein each of the plurality of HV battery string disconnects includes a first disconnect switch of the one or more disconnect switches.

4. The all-electric battery-operated machine of claim 1 , wherein the all-electric battery-operated machine is an all-electric battery-operated earth moving machine.

5. The all-electric battery-operated machine of claim 1 , wherein each said pair of the HV battery string modules, the corresponding pair of HV contactors, and the corresponding one of the HV battery string disconnections constitutes a High Voltage Interlock Loop (HVIL) circuit, the all-electric battery-operated machine thus having a plurality of the HVIL circuits.

6. The all-electric battery-operated machine of claim 1 ,
wherein the all-electric battery operated machine is an underground mine loader,
wherein the plurality of pairs of the HV battery string modules consist of n number of pairs of the HV battery string modules,
wherein the plurality of HV battery string disconnects consist of n HV battery string disconnects, and
wherein n is a positive integer greater than two.

7. The all-electric battery-operated machine of claim 6 , wherein n equals five.

8. The all-electric battery-operated machine of claim 6 , wherein n equals ten.

9. A method regarding voltage control for an all-electric battery-operated vehicle,
wherein the all-electric battery-operated vehicle includes:
a plurality of high voltage (HV) battery string modules configured to supply electric current to an inverter of the all-electric battery-operated vehicle, the plurality of HV battery string modules being grouped as a plurality of pairs of the HV battery string modules, including a first pair having a first HV battery string module and a second HV battery string module and a second pair having a third HV battery string module and a fourth HV battery string module;
a plurality of pairs of high voltage (HV) contactors respectively associated with each said pair of the HV battery string modules, including a first pair of HV contactors and a second pair of HV contactors, a first HV contactor of each of the plurality of pairs of HV contactors being connected to a positive terminal of the inverter of the all-electric battery-operated vehicle and a second HV contactor of each of the plurality of pairs of HV contactors being connected to a negative terminal of the inverter of the all-electric battery-operated vehicle;
a controller; and
a plurality of high voltage (HV) battery string disconnects, including a first HV battery string disconnect and a second HV battery string disconnect, each of the plurality of HV battery string disconnects including one or more disconnect switches, being electrically coupled to a corresponding pair of the plurality of pairs of the HV battery string modules and not any of the other pairs of the plurality of pairs of the HV battery string modules, including the first HV battery string disconnect being electrically connected between the first and second HV battery string modules and the second HV battery string disconnect being electrically connected between the third and fourth HV battery string modules, and being electrically connected directly to the controller,
wherein the method comprises:
supplying electric current from the plurality of HV battery string modules to the inverter of the all-electric battery-operated vehicle;
opening, under control of the controller, and in response to opening of the one or more disconnect switches of the first HV battery string disconnect, at least one of the first HV contactor or the second HV contactor of the first pair of HV contactors to disconnect the first pair of HV battery string modules without disconnecting any other pair of HV battery string modules;
stopping supply of the electric current from the disconnected corresponding pair of HV battery string modules to the inverter responsive to opening of the at least one of the HV contactors of one of the pairs of HV contactors; and
continuing to supply the electric current to the inverter of the all-electric battery-operated vehicle from all other pairs of HV battery string modules of the plurality of HV battery string modules, apart from the first pair of HV battery string modules having been disconnected while the first pair of HV battery string modules remain disconnected,
wherein each of the plurality of HV battery string disconnects

Assignees

• Caterpillar Inc

Inventors

• Baumann Jonathan M
• Middleton Justin Dale
• Miller Jason Lee
• Stumpges Evan Blair

Classifications

• H02J7/56

  Active balancing, e.g. using capacitor-based, inductor-based or DC-DC converters · CPC title

• H02J7/54 Primary

  Passive balancing, e.g. using resistors or parallel MOSFETs · CPC title

• H02J2105/37

  exchanging power with electric vehicles [EV] or with hybrid electric vehicles [HEV] · CPC title

• H02J7/855

  with circuits adapted for supplying loads from the battery · CPC title

• H02J7/585 Primary

  Sequential battery discharge in systems with a plurality of batteries · CPC title