Ford Global Technolgoies, LLC

Ai Keramidas

Benjamin A Tabatowski-Bush

Patterson Kaduvinal Abraham

John Paul Gibeau

Derek Hartl

Daniel Paul Roberts

Wesley Burkman

Aaron Walker

Kimberley King

Baojin Wang

Rui Wang

Ben A Tabatowski-Bush

Methods and systems are provided for a high-voltage multi-array battery of a plug-in vehicle. In one example, a method may include monitoring a rate of change of a difference in a maximum cell voltage deviation for at least one array of cells of the high-voltage multi-array battery exceeding a predetermined threshold. In response to the rate of change exceeding the predetermined threshold, plug-in charging is aborted and a diagnostic trouble code (DTC) is recorded in a memory of the vehicle.

Systems and methods for battery cell degradation detection

An electrified vehicle includes a contactor having a coil operable by a low-voltage control signal to selectively electrically couple a terminal of a high-voltage bus to a charger receiving power from an external source. A programmed controller predicts the time it will take for the contactor to close after receiving a command based on the coil temperature and voltage of the command signal. The controller generates the low-voltage control signal responsive to a difference between bus voltage and charger voltage being less than a first threshold at the predicted closing time of the contactor. The control signal may also depend on the rate of change of the charger voltage being below a second threshold.

Electrified vehicle high voltage contactor control

A vehicle has a battery including a plurality of cells connected in series, and a battery management integrated circuit including a plurality of inputs each being directly electrically connected to a terminal of one of the cells via an electrical path that includes a fuse and a resistor connected in series. The battery management integrated circuit further includes a top input directly electrically connected to a positive output of the battery and configured to receive power from the battery that is defined by a current having a magnitude that is at least an order of magnitude greater than current received by the inputs and a voltage equal to a sum of voltages of all the cells. The battery management integrated circuit is configured to calculate a voltage difference between one of the inputs and an adjacent one of the inputs to determine a voltage of a top cell of the battery cells and to correct the voltage of the top cell to form a corrected voltage as a sum of the voltage of the top cell and a calculated voltage drop across the fuse in the electrical path between the top cell and the one of the inputs. The vehicle further has a controller programmed to balance the cells according to the corrected voltage of the top cell.

Automotive battery system control according to corrected top cell voltage

A method for monitoring contactor health according to an exemplary aspect of the present disclosure includes, among other things, storing wear data associated with a contactor, categorizing the wear data into at least a first bin and a second bin, assigning a first health level to the wear data associated with the first bin and assigning a second health level to the wear data associated with the second bin. Health information concerning the contactor is communicated to the vehicle operator.

System and method for monitoring contactor health

A vehicle includes a traction battery and a battery management system. The battery management system includes a controller programmed to output a drained cell diagnostic indicator. The drained cell diagnostic indicator is based on a magnitude of a difference between an average cell state of charge at a start of a battery rest period and a cell state of charge estimated at predetermined intervals during the battery rest period being greater than a predetermined value. A response to the drained cell diagnostic indicator depends on the magnitude of the cell drain rate and may include operating the traction battery at a reduced power level and notifying an operator of the diagnostic condition.

Circuit and method for detection of battery cell drain

A multi-cell battery pack in an electric vehicle is monitored by multiple sensing modules. A primary controller is coupled to a first plurality of cells to measure a predetermined parameter of each cell. The primary controller determines a sampling moment recurring at a fixed frequency for sampling the predetermined parameter of each of the first plurality of cells. The primary controller generates a sync pulse at each sample moment. A secondary controller is coupled to a second plurality of cells to measure the predetermined parameter of each cell. The secondary controller receives the sync pulse to start a pulse generator operating at a frequency which is a predetermined multiple of the primary controller fixed frequency. The secondary controller counts pulses generated by the pulse generator and schedules a synchronized secondary sampling moment according to a predetermined pulse count.

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West Bloomfield, MI, United States of America

Ai Keramidas