Methods, apparatus, and systems for preventing over-temperature battery operation

Patent metadata

Field	Value
Publication number	US-2016200216-A1
Application number	US-201514595058-A
Country	US
Kind code	A1
Filing date	Jan 12, 2015
Priority date	Jan 12, 2015
Publication date	Jul 14, 2016
Grant date	—

Abstract

Methods and systems for preventing over-temperature conditions in vehicle battery packs. In some implementations, such methods may comprise measuring a resistance within a contactor of an electric vehicle, estimating a temperature of the contactor using the measured resistance, and comparing the estimated temperature of the contactor with a threshold temperature. In some implementations, upon determining that the estimated temperature has exceeded the threshold temperature, the current delivered through the contactor may be limited.

First claim

1 . A method for limiting the operating temperature of a contactor within an electric vehicle, the method comprising the steps of:
measuring a resistance within a contactor of an electric vehicle; estimating a temperature of the contactor using the measured resistance; comparing the estimated temperature of the contactor with a threshold temperature; and upon determining that the estimated temperature has exceeded the threshold temperature, limiting current through the contactor.

2 . The method of claim 1 , wherein the step of measuring a resistance within a contactor of an electric vehicle comprises measuring a resistance within a coil of the contactor.

3 . The method of claim 1 , wherein the step of measuring a resistance within a contactor of an electric vehicle comprises measuring a voltage within the contactor and using the measured voltage to determine the resistance within the contactor.

4 . The method of claim 1 , wherein the threshold temperature is between about 130 degrees Celsius and about 180 degrees Celsius.

5 . The method of claim 1 , further comprising:
taking a plurality of temperature measurements of a contactor of an electric vehicle; taking a plurality of resistance measurements within the contactor associated with the plurality of temperature measurements; and correlating the resistance measurements with the temperature measurements.

6 . The method of claim 5 , wherein the step of correlating the resistance measurements with the temperature measurements comprises creating a lookup table from the temperature measurements and the resistance measurements.

7 . The method of claim 6 , wherein the step of estimating a temperature of the contactor using the measured resistance comprises using the lookup table to estimate the temperature of the contactor.

8 . The method of claim 1 , wherein the electric vehicle comprises a hybrid electric vehicle.

9 . A system for limiting the operating temperature of a contactor of a vehicle battery system, comprising:
a vehicle battery system; at least one sensor configured to measure at least one of a current and a resistance of at least a portion of the vehicle battery system; a temperature estimation module for estimating a temperature of at least a portion of the vehicle battery system, wherein the temperature estimation module is configured to receive battery data from the at least one sensor and estimate a temperature of the at least a portion of the vehicle battery system using the battery data; and a current control module for limiting a current through the vehicle battery system based upon estimated temperatures received from the temperature estimation module.

10 . The system of claim 9 , wherein the vehicle battery system comprises a contactor, and wherein the at least a portion of the vehicle battery system comprises at least a portion of the contactor.

11 . The system of claim 10 , wherein the battery data comprises at least one of a resistance, a voltage, and a current within the contactor.

12 . The system of claim 11 , wherein the current control module is configured to compare an estimated temperature received from the temperature estimation module with a threshold temperature and, upon determining that the estimated temperature has exceeded the threshold temperature, reduce the current through the contactor.

13 . The system of claim 9 , wherein the vehicle battery system comprises a high-voltage battery system, and wherein the vehicle comprises an electric vehicle.

14 . The system of claim 9 , wherein the current control module is configured to compare an estimated temperature with a threshold temperature and, upon determining that the estimated temperature has exceeded the threshold temperature, reduce the current through the at least a portion of the vehicle battery system.

15 . The system of claim 9 , wherein the temperature estimation module is configured to use a lookup table to estimate the temperature of the at least a portion of the vehicle battery system.

16 . The system of claim 15 , wherein the lookup table correlates temperature with resistance for the vehicle battery system.

17 . The system of claim 16 , wherein the vehicle battery system comprises a contactor, and wherein the lookup table correlates temperature within the contactor with resistance within the contactor.

18 . The system of claim 9 , wherein the current control module is configured to compare an estimated temperature received from the temperature estimation module with at least one threshold temperature and, upon determining that the estimated temperature has exceeded the at least one threshold temperature, reduce the current through the vehicle battery system.

19 . The system of claim 18 , wherein the at least one threshold temperature comprises a plurality of threshold temperatures, wherein the current control module is configured to compare an estimated temperature received from the temperature estimation module with a first threshold temperature of the plurality of threshold temperatures and, upon determining that the estimated temperature has exceeded the first threshold temperature, reduce the current through the vehicle battery system by a first amount, and wherein the current control module is configured to compare an estimated temperature received from the temperature estimation module with a second threshold temperature of the plurality of threshold temperatures and, upon determining that the estimated temperature has exceeded the second threshold temperature, reduce the current through the vehicle battery system by a second amount greater than the first amount.

20 . A system for limiting the operating temperature of a contactor within a high-voltage battery system of an electric vehicle, comprising:
a high-voltage vehicle battery system comprising a contactor; at least one sensor configured to measure a resistance of the contactor of the high-voltage vehicle battery system; a temperature estimation module for estimating a temperature of the contactor, wherein the temperature estimation module is configured to receive resistance data from the at least one sensor and estimate a temperature of the contactor using the resistance data by using a lookup table that correlates temperature within the contactor with resistance within the contactor; and a current control module coupled with the temperature estimation module, wherein the current control module is configured to compare an estimated temperature received from the temperature estimation module with at least one threshold temperature and, upon determining that the estimated temperature has exceeded the at least one threshold temperature, reduce the current through the contactor.

Assignees

• Gm Global Tech Operations Inc

Inventors

• Fultz Derek W
• Gonzalez Alessandro G

Classifications

• B60L11/1872 Primary

  Operations & Transport · mapped topic

• B60L11/1864

  Operations & Transport · mapped topic

• B60L58/25

  by controlling the electric load · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• Y02T10/70

  Energy storage systems for electromobility, e.g. batteries · CPC title