Ford Global Technolgoies, LLC

Gm Global Technolgoy Operations, Inc.

Eaton Corporation

Ford Global Technology, LLC

Chuan He

Xu Wang

Xiaoguang Chang

Josephine S Lee

Szushen Peter Ho

Michiel Jacques Van Nieuwstadt

Richard B Jess

David John Kubinski

Dave Charles Weber

Feng Li

Jay Tolsma

Haiyan Chen

Ruiqi Mao

James Edward McCarthy, Jr

Wenbo Wang

John F Van Gilder

Richard Dyche Anderson

Yun Xiao

Changjian Hu

GuoJun Shi

Zhimin Yang

Kouji Sakumoto

Jose L DeLeon

Kenneth Jon Cunningham

Jeffrey J Cowell

Brandon Swisher

A vehicle having a traction battery with at least one cell includes a controller coupled to the traction battery and programmed to modify traction battery current in response to a difference between a lithium plating parameter target value and a lithium plating parameter actual value to reduce the difference. The lithium plating parameter or indicator may be based on a differential open circuit voltage of a battery cell, or a ratio of differential voltage of the at least one cell as a function of time to cell charging rate of the at least one cell.

Closed loop feedback control to mitigate lithium plating in electrified vehicle battery

A vehicle includes a traction battery having cells and at least one controller. The controller is programmed to charge and discharge the traction battery according to a net current for the traction battery derived from sets of temperature-based current values, each of the sets corresponding to a different one of the cells, and each of the values for a given one of the sets corresponding to a different zone of the cell.

Traction battery with cell zone monitoring

A vehicle includes a traction battery. The vehicle further includes a controller programmed to generate a capacity estimate of the traction battery and, in response to an amount of energy supplied to the traction battery during a charge cycle being less than an estimated amount of energy stored in the traction battery during the charge cycle, detect that the capacity of the traction battery has changed and alter an operating strategy of the traction battery until the capacity estimate is updated.

System and method for online vehicle battery capacity diagnosis

A vehicle includes a traction battery and a controller in communication with the battery and programmed to control battery charging in response to a user-selected one of a plurality of charging strategies having different charging rates based on detection of lithium plating in the battery. The charging strategies may include options for faster charging with an urgent or emergency charging strategy selectable a limited number of times to mitigate battery performance degradation associated with lithium plating. A method implemented by a vehicle controller in a vehicle having a traction battery, may include controlling, by the controller, battery charging in response to a user-selected charging strategy selected from one of a plurality of available charging strategies each having a different charging rate and displayed on a user interface in response to detection of lithium plating in the traction battery, at least one charging strategy associated with additional lithium plating if selected.

Charging strategies to mitigate lithium plating in electrified vehicle battery

Lithium ion battery state of charge (SOC) is a function of open circuit voltage (OCV). Battery internal diffusion process needs to be nearly completed to be able to measure battery open circuit voltage. The length of the minimum settling time depends on the battery type, usage and temperature. Described are methods to determine electric vehicle battery voltage relaxation time based on battery temperature and usage history.

Methods to determine battery cell voltage relaxation time based on cell usage history and temperature

A vehicle includes a battery pack, an electric motor, and a contactor to electrically connect the pack and motor. The contactor is configured with a control circuit to electrically connect the pack and motor. The control circuit includes a leak detection sensor. The vehicle further includes a controller to output a leakage resistance associated with the pack. The leakage resistance is based on a voltage of the pack and a leak voltage detected by the sensor while the contactor is closed.

Methods and apparatus for detecting electrical leakage in a vehicle

A hybrid electric vehicle (HEV) and method of operation includes a thermal management system (TMS) that maintains optimal battery temperature operating ranges. The TMS includes a controller, heater, pump, and valves that control a flow rate of a convective fluid about the battery and other components. The TMS responds to battery temperature and differential signals, converting them into pump speed and heater signals utilizing a fuzzy logic multidimensional membership function (MF) that improves performance while reducing energy consumption by generating real-time, smoothed pulse width modulated (PWM) pump speed and heater signals. The MF capability requires less processing power than prior systems, which in turn enables improved response time to battery thermal and temperature rate changes during HEV operation. The MF utilizes embedded temperature and differential MFs that generate respective, real-time, tuned signal conversion factors, without the need for calibration look-up tables, to generate the PWM pump and heater control signals.

Battery thermal conditioning pump control for electric vehicle

A battery management system for a vehicle includes a controller programmed to charge a battery at a predetermined charge current. The controller activates an electrical load to discharge the battery for a predetermined time in response to a charge current of the battery becoming less than the predetermined charge current at a predetermined voltage limit. After discharging for the predetermined time, the controller resumes charging at the predetermined charge current. A current magnitude during the discharge and the predetermined time may be based on factors including the predetermined charge rate, a battery temperature, and a charge current magnitude during charging.

Battery charge strategy using discharge cycle

Vehicles that use electric power as a motive force may use accurate measurements of battery power for numerous purposes, e.g., battery characteristics, state of charge of the battery, travel distance remaining for the vehicle and the like. A traction battery measurement should be taken when the battery is fully relaxed, i.e., the battery is neither being charged nor providing power and a time period thereafter when the battery chemistry reaches a steady state. A controller or methods may determine if the battery is relaxed and if the battery is not relaxed, delay charging or discharging of the traction battery to allow accurate battery capacity determination. The controller may control a battery charger to ensure the battery is fully relaxed before sensing battery characteristics.

Estimating battery capacity in an electric vehicle

A vehicle having a traction battery with at least one cell includes a controller coupled to the traction battery and programmed to control charging and discharging of the traction battery in response to detecting lithium plating in the at least one cell indicated by a ratio of differential voltage of the at least one cell as a function of time to cell charging rate of the at least one cell. In various embodiments, the ratio is compared to a threshold associated with current battery state of charge to indicate lithium plating when the ratio is below the threshold. Lithium plating can also be detected based on a measured cell open circuit voltage (OCV) relative to a previously stored OCV value. In various embodiments, the measured OCV value is calculated based on a measured cell voltage and current, and a previously stored cell internal resistance.

Vehicle control based on lithium plating detection in electrified vehicle battery

A current sensor fault detection system is disclosed which enables detection of a current sensor fault while the current sensor is operating and providing a current sensor output which is within a normal operating range. The current sensor is monitored by at least one controller which compares a change in battery state of charge error with a predetermined threshold. The change in battery state of charge error is a difference between a first change in battery state of charge calculated by integrating battery current with respect to a time and a second change in battery state of charge calculated based on the battery open circuit voltage during the time.

In-range current sensor fault detection

A diagnostic method for contact resistance failure includes estimating electrical contact surface resistance of at least one contactor, determining a faulted status of the at least one contactor and indicating the faulted status of the at least one contactor if the at least one contactor is in the faulted status.

Diagnostic method for contactor resistance failure

Systems and methods for operating a battery pack supplying power to propel a vehicle are disclosed. One example method comprises, determining a difference between an estimated battery pack temperature and a sensed battery pack temperature as a basis for adjusting battery pack output power. The method also includes adjusting a speed of a cooling fan based on the difference between estimated battery pack temperature and sensed battery pack temperature.

System and method for operating a battery pack

A vehicle battery cooling system may include a cooling arrangement to cool a battery, and a controller programmed to operate the arrangement according to each of a series of estimated temperatures of the battery that are based on heat generation, stored thermal energy, and heat transfer rates associated with the battery such that the series forms an estimated temperature waveform that temporally leads a sensed temperature waveform of the battery.

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Northville, MI, United States of America

Chuan He