IP Library Granted Patent US 12686296
Granted Patent B2
US 12686296 · App. 18/708,736 · Granted Jul 21, 2026

System and methods for electric vehicle battery capacity determination and management

Inventors: Frederic Marangone (Louisville, CO); Nicolas Altenburger (Los Altos, CA); Christopher Satkoski (San Jose, CA)
Assignee: Tesla, Inc.
B60L58/13B60L58/16
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Quick Facts
Patent No.
US 12686296
App. No.
18/708,736
Granted
Jul 21, 2026
Kind
B2
Abstract

The present disclosure generally relates to systems and methods for managing a battery of an electric vehicle. In some embodiments, a system initiates battery discharging on a battery pack, where the battery discharging continues until the battery pack reaches a first threshold level of charge. The system then estimates a first state of charge of the battery pack based at least on a first sensor reading associated with the battery pack. The system initiates battery charging on the battery pack, where the battery charging continues until the battery pack reaches a second threshold level of charge. The system estimates a second state of charge of the battery pack based at least on a second sensor reading associated with the battery pack. The system generates a processing result that indicates a capacity of the battery pack based at least on the first state of charge and the second state of charge.

Claims (57)

1 . A system for managing a battery of an electric vehicle, the system comprising:

one or more processors configured to execute a battery capacity determination procedure, the battery capacity determination procedure comprising:

determining a current state of charge of a battery pack before initiating battery discharging and battery charging;

initiating the battery discharging, wherein the battery discharging discharges a battery pack until a charge state associated with the battery pack reaches a first threshold level of charge;

estimating a first state of charge of the battery pack based on the charge state associated with the battery pack reaching the first threshold level of charge;

initiating the battery charging, wherein the battery charging charges the battery pack until the charge state associated with the battery pack reaches a second threshold level of charge;

estimating a second state of charge of the battery pack based on the charge state associated with the battery pack reaching the second threshold level of charge; and

generating a processing result based at least on the first state of charge and the second state of charge, wherein the processing result comprises a capacity of the battery pack,

wherein the battery capacity determination procedure initiates the battery charging before initiating the battery discharging based on the current state of charge of the battery pack.

2 . The system of claim 1 , wherein the one or more processors is further configured to determine the charge state associated with the battery pack has reached a first steady state,

wherein the one or more processors estimates the first state of charge of the battery pack in response to determining the charge state associated with the battery pack has reached the first steady state.

3 . The system of claim 2 , wherein the one or more processors is further configured to determine the charge state associated with the battery pack has reached a second steady state,

wherein the one or more processors estimates the second state of charge of the battery pack in response to determining the charge state associated with the battery pack has reached the second steady state.

4 . The system of claim 1 , wherein generating the processing result comprises dividing the capacity of the battery pack by a nominal value to derive a capacity percentage, wherein the nominal value is obtained from the one or more processors executing the battery capacity determination procedure when the battery pack is at an initial condition.

5 . The system of claim 1 , wherein the one or more processors is further configured to:

obtain the battery capacity determination procedure from a battery charge vendor; and

obtain a request to determine battery pack capacity from a user,

wherein the one or more processors executes the battery capacity determination procedure in response to obtaining the request to determine battery pack capacity.

6 . The system of claim 1 , wherein the one or more processors is further configured to transmit the processing result to a user interface associated with the electric vehicle.

7 . The system of claim 1 , wherein the processing result further comprises at least one of a repair alert, a warranty or a certificate associated with the battery pack.

8 . The system of claim 1 , wherein the first threshold level of charge corresponds to a minimum state of charge of the battery pack and the second threshold level of charge corresponds to a maximum state of charge of the battery pack.

9 . The system of claim 1 , wherein at least a portion of the one or more processors is located remotely to the electric vehicle.

10 . The system of claim 1 , wherein initiating the battery discharging comprises discharging the battery pack using at least one of a heater, a compressor or a waste energy mode of the electric vehicle.

11 . The system of claim 1 , wherein initiating the battery discharging comprises discharging the battery pack using a bi-directional power equipment, and wherein initiating the battery charging comprises charging the battery pack using the bi-directional power equipment.

12 . A computer-implemented method comprising:

executing, by one or more processors of an electric vehicle, a battery capacity determination procedure, the battery capacity determination procedure comprising:

determining a current state of charge of a battery pack before initiating battery discharging and battery charging;

initiating the battery discharging, wherein the battery discharging discharges a battery pack until a charge state associated with the battery pack reaches a first threshold level of charge;

estimating a first state of charge of the battery pack based at least on a first sensor reading associated with the battery pack and the charge state associated with the battery pack reaching the first threshold level of charge;

initiating the battery charging, wherein the battery charging charges the battery pack until the charge state associated with the battery pack reaches a second threshold level of charge;

estimating a second state of charge of the battery pack based at least on a second sensor reading associated with the battery pack and the charge state associated with the battery pack reaching the second threshold level of charge; and

generating a processing result associated with the battery pack based at least on the first state of charge and the second state of charge,

wherein the battery capacity determination procedure initiates the battery charging before initiating the battery discharging based on the current state of charge of the battery pack.

13 . The computer-implemented method of claim 12 , further comprising:

obtaining the battery capacity determination procedure from a battery charge vendor; and

obtaining a request to determine battery pack capacity from a user,

wherein the one or more processors executes the battery capacity determination procedure in response to obtaining the request to determine battery pack capacity.

14 . The computer-implemented method of claim 12 , further comprising determining the charge state associated with the battery pack has reached a first steady state,

wherein the one or more processors determines the charge state associated with the battery pack has reached the first steady state based on a timing-based criteria; and

wherein the one or more processors estimates the first state of charge of the battery pack in response to determining the charge state associated with the battery pack has reached the first steady state.

15 . The computer-implemented method of claim 12 , further comprising determining the charge state associated with the battery pack has reached a first steady state,

wherein the one or more processors determines the charge state associated with the battery pack has reached the first steady state based on a confidence bound; and

wherein the one or more processors estimates the first state of charge of the battery pack in response to determining the charge state associated with the battery pack has reached the first steady state.

16 . One or more non-transitory computer-readable media comprising instructions executable at one or more processors of an electric vehicle, wherein the instructions comprise a battery capacity determination procedure, and wherein the battery capacity determination procedure, when executed by the one or more processors, causes the one or more processors to:

determine a current state of charge of a battery pack before initiating battery discharging and battery charging;

initiate the battery discharging, wherein the battery discharging discharges a battery pack until a charge state associated with the battery pack reaches a first threshold level of charge;

estimate a first state of charge of the battery pack based on the charge state associated with the battery pack reaching the first threshold level of charge;

initiate the battery charging, wherein the battery charging charges the battery pack until the charge state associated with the battery pack reaches a second threshold level of charge;

estimate a second state of charge of the battery pack based on the charge state associated with the battery pack reaching the second threshold level of charge; and

calculate a capacity of the battery pack based at least on the first state of charge and the second state of charge,

wherein the battery capacity determination procedure initiates the battery charging before initiating the battery discharging based on the current state of charge of the battery pack.

17 . The one or more non-transitory computer-readable media of claim 16 , wherein the instructions further cause the one or more processors to determine the charge state associated with the battery pack has reached a first steady state, and wherein the one or more processors estimates the first state of charge of the battery pack in response to determining the charge state associated with the battery pack has reached the first steady state.

18 . The one or more non-transitory computer-readable media of claim 16 , wherein the instructions further cause the one or more processors to perform, based at least on the capacity of the battery pack, operations including one of:

adjusting one or more parameters of a battery management system (BMS) of the electric vehicle;

generating a repair alert associated with the battery pack; or

generating a warranty certificate associated with the battery pack.

19 . The one or more non-transitory computer-readable media of claim 16 , wherein the first threshold level of charge corresponds to a minimum state of charge of the battery pack and the second threshold level of charge corresponds to a maximum state of charge of the battery pack.