Large-format battery management systems with gateway PCBA
A battery system with a large-format Li-ion battery pack powers attached equipment by discharging battery cells distributed among a plurality of battery packs. A limp home notification is generated from a smart lithium-ion battery pack to one or more application devices using an analog signal. The battery pack may provide broadcast messages over electronic communication lines, that includes state of charge (SoC), fault status, etc. which can be read by one or more application devices to enter limp home mode. In another example, a “fully charged” notification is generated from the smart lithium-ion battery pack to one or more application devices using an analog signal. The end device powered by the battery pack system receives and reacts to the outputted fully charged signal by modifying the state of the circuitry on the end device.
1. A first battery pack configured for installation in a battery system of a plurality of battery packs, the first battery pack comprising:
one or more battery cells;
a power bus interface circuit configured to interface with a power bus and to provide electrical power from the one or more battery cells;
a switch;
a gateway connector, connected to the switch, configured to output a signal;
a controller comprising at least one processor; and
a memory storing instructions that, when executed by the at least one processor, cause the controller to:
determine, based on receiving a failure notification message indicative of a catastrophic failure at a second battery pack, whether a first spare battery pack is available;
disable, based on a determination that no spare battery pack is available, the second battery pack from discharging onto the power bus;
output, based on the determination that no spare battery pack is available, a degradation alert message, for an end device, via the gateway connector, wherein the degradation alert message identifies a degradation of power available from the plurality of battery packs in the battery system; and
output, based on the output of the degradation alert message and via the gateway connector, a limp home mode signal.
2. The first battery pack of claim 1 , wherein the power bus interface circuit comprises a gateway printed circuit board assembly (PCBA).
3. The first battery pack of claim 1 , wherein the end device is powered by a non-smart battery.
4. The first battery pack of claim 1 , wherein the instructions to output the limp home mode signal further include instructions to control the controller to cause a hardware pin, corresponding to a limp home mode on the end device, to be set.
5. The first battery pack of claim 1 , wherein the instructions, when executed by the at least one processor, further cause the controller to:
store a lookup table comprising different state of charge threshold values corresponding to different temperature readings.
6. The first battery pack of claim 1 , wherein the instructions, when executed by the at least one processor, further cause the controller to:
store a lookup table comprising different state of charge threshold values corresponding to different numbers of battery packs installed in the battery system.
7. The first battery pack of claim 1 , wherein the first battery pack receiving the failure notification message indicative of the catastrophic failure at the second battery pack is based on one or more criteria in a lookup table storing different state of charge threshold values.
8. The first battery pack of claim 1 , wherein the first battery pack receiving the failure notification message indicative of the catastrophic failure at the second battery pack is based on one or more battery cells of the second battery pack having a state of charge value below a predetermined threshold.
9. The first battery pack of claim 1 , wherein the instructions to output the limp home mode signal comprise instructions to further control the switch to output a preset regulated voltage.
10. The first battery pack of claim 1 , wherein the instructions, when executed by the at least one processor, further cause the controller to:
determining the end device has not complied with the degraded alert message; and
initiate shutdown of the battery system.
11. The first battery pack of claim 2 , wherein the gateway printed circuit board assembly (PCBA) is configured to read state of charge (SoC) data over an electronic communication protocol.
12. The first battery pack of claim 1 , wherein the instructions, when executed by the at least one processor, further cause the controller to:
determine, at a time after the determination that no spare battery pack is available, that a spare battery pack is available;
determine, based on the determination a spare battery pack is available, that at least an additional battery pack is needed;
send, based on the determination that at least an additional battery pack is needed, an enable message to the spare battery pack, wherein the enable message instructs the spare battery pack to discharge power onto the power bus; and
deactivate the limp home mode signal.
13. A method comprising:
determining, at a first battery pack of battery packs based on receiving a failure notification message indicative of a catastrophic failure at a second battery pack, whether a first spare battery pack is available;
disabling, based on the determining that no spare battery pack is available, the second battery pack from discharging onto a power bus;
outputting, via a power bus interface circuit based on the determining that no spare battery pack is available, a degradation alert message, for an end device, via a gateway connector, wherein the degradation alert message identifies a degradation of power available from the battery packs; and
outputting, based on the outputting of the degradation alert message and via a gateway connector, a limp home mode signal.
14. The method of claim 13 , wherein the power bus interface circuit comprises a gateway printed circuit board assembly (PCBA).
15. The method of claim 13 , wherein the end device is powered by a non-smart battery.
16. The method of claim 13 , wherein outputting the limp home mode signal comprises causing, in the end device, a hardware pin to be set.
17. The method of claim 13 , wherein receiving the failure notification message is based on one or more criteria in a lookup table storing different state of charge threshold values.
18. The method of claim 13 , wherein receiving the failure notification message is based on one or more battery cells of the second battery pack having a state of charge value below a predetermined threshold.
19. The method of claim 13 , wherein outputting the limp home mode signal comprises controlling a switch to output a preset regulated voltage.
20. A battery system configured for electrically powering an end device and comprising a plurality of battery packs, the battery system comprising:
a power bus;
a slave battery pack; and
a master battery pack including:
a switch;
a gateway connector, connected to the switch and communicatively coupled with a power bus interface circuit, configured to provide a signal to an input line of the end device;
a controller comprising at least one processor; and
a memory storing instructions that, when executed by the at least one processor, cause the controller to:
determine, based on receiving a failure notification message indicative of a catastrophic failure at the slave battery pack, whether a first spare battery pack is available;
disable, based on a determination that no spare battery pack is available, the slave battery pack from discharging onto the power bus;
output, based on the determination that no spare battery pack is available, a degradation alert message, for the end device, via the gateway connector, wherein the degradation alert message identifies a degradation of power available from the plurality of battery packs in the battery system; and
output, based on the output of the degradation alert message and via the gateway connector, a limp home mode signal.