IP Library Granted Patent US 10,868,430
Granted Patent B1
US 10,868,430 · App. 16/856,605 · Granted Dec 15, 2020

Multi-battery charging station which selectively connects battery sub-modules to a common power bus for charging

Inventors: Lewis Romeo Hom (Mountain View, CA); Brian Robert Viele (Crozet, VA); Scott Furman (Menlo Park, CA)
Assignee: WISK AERO LLC
H02J7/00H02J7/0013H02J7/0069H05K7/20136
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Quick Facts
Patent No.
US 10,868,430
App. No.
16/856,605
Granted
Dec 15, 2020
Kind
B1
Abstract

Battery sub-modules are selecting to electrically connect to a common power bus, including by: determining if a discharge-related fault indication for a given battery sub-module indicates that the given battery sub-module is in a discharge-related fault condition. If so, the given battery sub-module is excluded from the selected battery sub-modules such that said given battery sub-module is electrically disconnected from the common power bus. The selected battery sub-modules are configured so that the selected battery sub-modules are electrically connected to the common power bus; the selected battery sub-modules that are electrically connected to the common power bus are charged.

Claims (65)

1. A system, comprising:

a power bus;

a plurality of battery sub-modules connected to the power bus;

a charger interface coupled to the plurality of battery sub-modules;

a charger coupled to the charger interface and configured to:

charge one or more of the plurality of battery sub-modules;

receive, via the charger interface, a plurality of metrics associated with the plurality of battery sub-modules, wherein the plurality of metrics include a first metric associated with a first battery sub-module;

minimize a charging time of the first battery sub-module based on the first metric via the charger interface.

2. The system of claim 1 , wherein charger is further configured to:

select a first set of battery sub-modules among the plurality of battery sub-modules based on the metrics associated with the one or more battery sub-modules, wherein the first set of battery sub-modules are determined to collectively charge faster than remaining battery sub-modules; and

charge the first set of battery sub-modules.

3. The system of claim 1 , wherein the plurality of metrics are dynamic values that are received periodically from the plurality of battery sub-modules with a frequency of once every one or more charging cycles.

4. The system of claim 1 , wherein the plurality of metrics are received periodically from the plurality of battery sub-modules when a predetermined event occurs.

5. The system of claim 1 , further comprising:

a battery management system coupled to each one of the plurality of battery sub-modules, wherein a first battery management system coupled to the first battery sub-module is configured to estimate or measure the first metric for the first battery sub-module.

6. The system of claim 1 , further comprising:

a battery management system coupled to each one of the plurality of battery sub-modules, wherein a given battery management system coupled to a given battery sub-module is configured to detect that the given battery sub-module is in a fault state, and inform the charger that the given battery sub-module is in the fault state.

7. The system of claim 6 , wherein charger is further configured to:

disconnect the given battery sub-module from the power bus.

8. The system of claim 1 , wherein the plurality of metrics include one or more of a temperature, a state of charge, a maximum cell voltage, and a minimum current associated with each battery sub-module among the plurality of battery sub-modules.

9. The system of claim 1 , wherein the plurality of metrics include a set of metrics associated with each battery sub-module, wherein a charging state for a given battery sub-module is based on a totality of the set of metrics associated with the given battery sub-module.

10. The system of claim 1 , wherein the charger is further configured to:

charge the plurality of battery sub-modules in a constant current state mode where the charger maintains a charging current value at a predetermined constant charging current;

determine that a maximum cell voltage for a given battery sub-module among the plurality of battery sub-modules reached a threshold value; and

switch from the constant current state mode to a constant cell voltage state mode where the charger sets the charging current value to a value to maintain the maximum cell voltage at a predetermined value.

11. The system of claim 1 , wherein the charger is further configured to:

stop charging the plurality of battery sub-modules when a charging current value of the charger drops to a predetermined value.

12. The system of claim 1 , wherein the charger is further configured to:

stop charging the plurality of battery sub-modules when a charging time exceeds a predetermined threshold.

13. The system of claim 1 , wherein the charger is further configured to:

determine a minimum battery sub-module current, wherein the minimum battery sub-module current is lowest among battery sub-module currents associated with the plurality of battery sub-modules;

charge the plurality of battery sub-modules at a first charging current set based on at least the minimum battery sub-module current;

obtain a global maximum cell voltage, wherein the global maximum cell voltage is highest among maximum cell voltages associated with the plurality of battery sub-modules; and

charge the plurality of battery sub-modules at a second charging current set based on at least the global maximum cell voltage until the global maximum cell voltage exceeds a threshold value.

14. The system of claim 1 , further comprising:

a heating and cooling system associated with one or more battery sub-modules,

wherein the charger is further configured to:

receive a temperature of a given battery sub-module among the plurality of battery sub-modules;

determine that the temperature of the given battery sub-module is outside a predetermined range; and

activate the heating and cooling system via the charger interface to heat or cool the given battery sub-module; and

start charging the given battery sub-module when the temperature of the given battery sub-module is within the predetermined range.

15. The system of claim 14 , wherein the heating and cooling system includes one or more heating coils associated with one or more battery sub-modules.

16. The system of claim 1 , wherein the charger is further configured to:

determine a given battery sub-module with a state of charge that is at a target maximum cell voltage; and

discharge the given battery sub-module.

17. A system, comprising:

a power bus;

a plurality of battery sub-modules connected to the power bus;

a charger interface coupled to the plurality of battery sub-modules;

a charger coupled to the charger interface and configured to:

determine a minimum battery sub-module current, wherein the minimum battery sub-module current is lowest among battery sub-module currents associated with the plurality of battery sub-modules;

charge the plurality of battery sub-modules at a first charging current set based on at least the minimum battery sub-module current;

obtain a global maximum cell voltage, wherein the global maximum cell voltage is highest among maximum cell voltages associated with the plurality of battery sub-modules; and

charge the plurality of battery sub-modules at a second charging current set based on at least the global maximum cell voltage until the global maximum cell voltage exceeds a threshold value.

18. The system of claim 17 , wherein the charger is further configured to:

stop charging the plurality of battery sub-modules when a charging current value of the charger drops to a predetermined value or when a charging time exceeds a predetermined threshold.

19. A system, comprising:

a power bus;

a plurality of battery sub-modules connected to the power bus;

a charger interface coupled to the plurality of battery sub-modules;

a charger coupled to the charger interface and configured to:

charge the plurality of battery sub-modules in a constant current state mode where the charger maintains a charging current value at a predetermined constant charging current;

determine that a maximum cell voltage for a given battery sub-module among the plurality of battery sub-modules reached a threshold value; and

switch from the constant current state mode to a constant cell voltage state mode where the charger sets the charging current value to a value to maintain the maximum cell voltage at a predetermined value.

20. The system of claim 19 , wherein the charger is further configured to: stop charging the plurality of battery sub-modules when a charging current value of the charger drops to a predetermined value or when a charging time exceeds a predetermined threshold.

Assignments (3)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 23, 2020
From: HOM, LEWIS ROMEO; VIELE, BRIAN ROBERT; FURMAN, SCOTT
To: KITTY HAWK CORPORATION
Reel/Frame 052478/0909 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 23, 2020
From: KITTY HAWK CORPORATION
To: CORA AERO LLC
Reel/Frame 052478/0962 →
CHANGE OF NAME Recorded Apr 23, 2020
From: CORA AERO LLC
To: WISK AERO LLC
Reel/Frame 052482/0538 →
Continuity (3)
Continuation 16405218 · May 7, 2019
Continuation 16135851 · Sep 19, 2018
Continuation 15885303 · Jan 31, 2018
Cited By (3)
US 12,466,291 US 12,633,762 US 12,689,225