Ford Global Technolgoies, LLC

Rui Wang

Xu Wang

Yuan Zhang

Xiao Guang Yang

Baojin Wang

Patterson Kaduvinal Abraham

Aaron Walker

Xianzhi Gong

Chingchi Chen

Benjamin A Tabatowski-Bush

John Paul Gibeau

Wesley Burkman

Jeffery R Grimes

Ai Keramidas

Changjian Hu

Hesam Zomorodi Moghadam

Jeffrey R Grimes

Andrea Cordoba Arenas

Rui Hu

A power distribution system includes a contactor between a traction battery and a high-voltage bus. The system includes a controller configured to generate a contactor status to determine if the contactor is operating as commanded. The controller identifies a contactor as closed responsive to a rate of change of a voltage difference between a traction battery voltage and a high-voltage bus voltage over each of a predetermined number of time intervals being within a predetermined range.

System and method for contactor status check for electrified vehicle

A vehicle battery system includes a battery, storage, and one or more controllers. The storage maintains data defining power outputs for the battery at a plurality of predefined combinations of temperature and state of charge. The one or more controllers repeatedly update the data for some of the plurality based on temperatures and states of charge repeatedly encountered by the vehicle, update the data for other of the plurality based on data from a remote server, and discharge the battery according to the data for the some and other of the plurality.

System and method for operating vehicle based on battery health

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 controller, during charging of a traction battery by a remote charger, and responsive to a difference between a requested charge current and a current supplied by the remote charger exceeding a first threshold value for a predefined period of time, increases a requested charge voltage to a limit value. The controller further, responsive to a voltage across a capacitor and a voltage across the traction battery being same, and a voltage of the remote charger and the limit value being same, commands the remote charger to discontinue the charging.

Control and diagnosis of charging system for a vehicle

A power system includes a battery and a controller. The controller inhibits charge of the battery according to voltage or current values sensed before and after contactors electrically connected to the battery are commanded to open and indicating that a leakage resistance associated with one of the contactors increases after the one of contactors is commanded to open, and a duration of a continuous voltage drop across another of the contactors after the another of the contactors is commanded to open exceeds a threshold.

Method and system for detecting contactor weld

Methods and system are described for recalibrating a charge storage capacity value of an electric energy storage device. In one example, the charge electric energy storage device may be a battery. The charge storage capacity value may be recalibrated via discharging and charging a battery via electric vehicle supply equipment.

System and method for recalibrating a traction battery through bi-directional power transfer

A vehicle includes a traction battery and a controller. The controller, responsive to some cells of the traction battery achieving a first state of charge threshold, discharge other cells of the traction battery, each having a capacity greater than each of the some of the cells, to a second state of charge threshold that is greater than the first state of charge threshold without discharging the some of the cells. The controller then charges all of the cells at the same time such that the some of the cells and the other of the cells achieve a same predetermined target state of charge at a same time.

Cell capacity based battery pack balancing

Methods and system are described for estimating an amount of battery usage for a traction battery of a vehicle. The traction battery usage estimate may be based on or a function of a distance per gallon of gasoline-equivalent so that the usage estimate may be more familiar to vehicle operators. In addition, the traction battery usage estimate may also be based on traction battery current and traction battery voltage.

System and method for quantifying battery usage

A vehicle includes charger contactors configured to selectively electrically couple terminals for connecting to a charger to corresponding terminals of a high-voltage bus. The vehicle includes a precharge contactor configured to selectively couple a terminal of a battery to the high-voltage bus through an impedance element. The vehicle includes a controller programmed to command the charger contactors to an open state for a drive cycle and command the precharge contactor to close at a start of the drive cycle and, responsive to a voltage across the terminals for connecting to the charger changing from being less than a first predetermined voltage immediately prior to the precharge contactor being closed to being greater than a second predetermined voltage at a completion of precharging, inhibit vehicle operation and disconnect the battery from the high-voltage bus.

System and method for charger contactor double weld detection

A vehicle includes a traction battery having a plurality of battery cells and a balance circuit configured to selectively discharge one or more of the battery cells. A controller is programmed to estimate charge capacities of the battery cells and determine a standard deviation of the estimated capacities. The controller is further programmed to determine a skewness of the estimated capacities. The controller is also programmed to, in response to the skewness exceeding a first threshold, command the balance circuit to discharge one or more of the battery cells when a state of charge (SOC) of the traction battery is less than a second threshold, and, in response to the skewness being less than the first threshold, command the balance circuit to discharge one or more of the battery cells when the SOC of the traction battery is greater than the second threshold.

Balancing cells of a traction battery using statistical analysis

A vehicle includes an electric machine, a battery, and a controller. The electric machine is configured to deliver power to wheels to drive the vehicle. The battery has an array of cells that are configured to deliver electrical power to the electric machine. The controller is programmed to, in response to a charge imbalance within the array of cells, simultaneously discharge a number of cells within the array based on a temperature of the controller.

Battery cell rebalancing method

An electrified vehicle includes a traction battery that is operated according to a state of charge of the traction battery. A controller is programmed to operate the traction battery according to the state of charge of the traction battery and, in response to completion of a charge cycle of the traction battery, generates an adaptive relaxation time and an adaptive compensation voltage of the state of charge that changes with a temperature and a charge rate of the traction battery. The controller is further programmed to, in response to expiration of the adaptive relaxation time after completion of the charge cycle, update the state of charge to a value corresponding to a voltage defined by a difference between a measured voltage of the traction battery and the adaptive compensation voltage.

Adaptive open circuit voltage based soc reset method at the end of charge based on temperature and charging rate

A power distribution system for a vehicle includes contactors that selectively electrically couple a charger to a high-voltage bus. The contactors are closed at the start of a charge event in an order that alternates for successive charge events. Upon completion of the charge event, the last closed contactor at the start of the charge event is opened first and a weld check is performed. If the weld check is indicative of a welded contactor, then the weld check is performed on the other contactor.

System and method for charge contactor weld check

A system comprises a processor, configured to perform balancing on a commanded cell referring to a reference cell, and responsive to detecting balancing time exceeding a threshold time and state of charge (SOC) difference being above a tolerance, abort the balancing, and generate an error message. The threshold time depends on an average balancing time calculated using the SOC difference, a predetermined commanded cell capacity, and a predetermined balancing current.

System and method for battery cell balancing

A system for a vehicle including a traction battery, electrical loads, and a controller configured to, during a charge operation, activate the loads such that charge current output by a charger is consumed by the loads and charge current input to the battery approaches zero to update a state of charge (SOC) value of the battery, and deactivate the loads upon completion of the update such that charge current input to the battery increases.

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Canton, MI, United States of America

Rui Wang