Ford Global Technolgoies, LLC

Yuan Zhang

Rui Wang

Xu Wang

Navid Rahbari Asr

Michael W Degner

Xiao Guang Yang

Jeffery R Grimes

Lila Ghannam

Wai Hwa Fong

Changjian Hu

Carol Louise Okubo

Jonathan Andrew Butcher

Aaron Walker

Matthew Roger Dedona

Timothy Harris

Kevin Vander Laan

Toussaint Carpenter

Patterson Kaduvinal Abraham

Graham Lynn Briggs

Jeffrey R Grimes

Xianzhi Gong

Ling Jin

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 includes control pilot circuitry connected with a charge port and including a control pilot line, a resistor, and a switch that selectively connects the resistor between the control pilot line and a ground of electric vehicle supply equipment plugged into the charge port. The vehicle also includes a controller that toggles the switch between open and closed states after receiving an off-board request defining a number of toggles for the switch.

Vehicle-electric vehicle supply equipment connection confirmation

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 vehicle power system includes at least one main switch to electrically connect a traction battery and electric machine, at least one DC charge switch to electrically connect the traction battery and a DC charge port when the at least one main switch is closed, and a controller to, while the DC charge port is disconnected from a DC power source, sequentially close the at least one DC charge switch and then the at least one main switch.

Isolation fault detection on DC charge bus

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 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 vehicle includes a traction battery; a bus; a main contactor between the traction battery and bus; a precharge contactor between the traction battery and bus in parallel with the main contactor; and a controller configured to, responsive to a first precharge mode signal, command a charging station to increase a voltage on the bus and subsequently close the precharge contactor before closing the main contactor, and responsive to a second precharge mode signal, close the precharge contactor without first commanding the charging station to increase the voltage on the bus before closing the main contactor.

Precharging for direct current fast charging

A vehicle includes a contactor electrically between a charge port and a traction battery, and a controller configured to maintain the contactor in a closed position until a charge current estimate, derived from vehicle load data without sensing current through the contactor or receiving data from a charge station regarding the current, is less than a predetermined threshold. The maintenance of the contactor position is responsive to a charge disconnect request.

Charge port contactor operation

An electrified vehicle includes a global positioning system (GPS) module. The vehicle further includes a controller programmed to learn a source identification for a charging error during charge events. The controller receives location data corresponding to each charging error and utilizes the location data to determine the source identification. The source identification may be indicative of the vehicle, an offboard charger, and the operator. Errors that occur consistently at multiple locations may be assigned a higher probability of being identified as vehicle-related errors.

Neuro-adaptive onboard/offboard fault detector for digital charging

A vehicle charging system includes a charger configured to adjust an output voltage to achieve a voltage request and output a measured output voltage. The vehicle charging system further includes a controller programmed to measure a terminal voltage of a traction battery being charged and receive the measured output voltage from the charger. The controller is further programmed to output the voltage request as a sum of a full charge voltage and an estimated voltage measurement error between the measured output voltage and the terminal voltage.

Electrified vehicle measurement error compensating charge voltage request

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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Southgate, MI, United States of America

Yuan Zhang