Systems for determining a voltage out-of-range high condition and a voltage out-of-range low condition of a battery module

A system for determining a voltage out-of-range high condition of a battery module;

• the battery module having at least first, second, and third battery cells, comprising:
• a first voltage sensor being electrically coupled to the first battery cell, the first voltage sensor outputting a first signal indicating a first voltage level being output by the first battery cell;
• a second voltage sensor being electrically coupled to the second battery cell, the second voltage sensor outputting a second signal indicating a second voltage level being output by the second battery cell;
• a third voltage sensor being electrically coupled to the third battery cell, the third voltage sensor outputting a third signal indicating a third voltage level being output by the third battery cell;
• a battery module voltage sensor being electrically coupled to the battery module, the battery module voltage sensor outputting a fourth signal indicating a battery module voltage level being output by the battery module;
• a microcontroller operably coupled to the first, second, and third voltage sensors, the battery module voltage sensor, and a memory device;
• the memory device having a battery module voltage out-of-range high error value corresponding to a square root of a first sum of squares value therein, the first sum of squares value corresponding to a sum of first, second, and third battery cell weighted voltage measurement error square values and a battery module voltage measurement error square value;
• the microcontroller determines first, second, and third voltage values based on the first, second, and third signals, respectively;
• the microcontroller further determines a battery module voltage value based on the fourth signal;
• the microcontroller further determines if at least one of the first voltage value, the second voltage value, and the third voltage value is greater than a desired maximum cell voltage value;
• the microcontroller further replaces the at least one of the first voltage value, the second voltage value, and the third voltage value that is greater than the desired maximum cell voltage value with a desired cell voltage value, the desired cell voltage value being less than the desired maximum cell voltage value;
• the microcontroller further sums the first voltage value, the second voltage value, and the third voltage value to obtain a battery module high voltage sum value;
• and
• the microcontroller further generates a first control signal to induce a contactor to transition from a closed operational position to an open operational position to electrically decouple the battery module from an electrical load, if a difference between the battery module high voltage sum value and the battery module voltage value is greater than or equal to the battery module voltage out-of-range high error value indicating the voltage out-of-range high condition.

A system for determining a voltage out-of-range low condition of a battery module;

• the battery module having at least first, second, and third battery cells, comprising:
• a first voltage sensor being electrically coupled to the first battery cell, the first voltage sensor outputting a first signal indicating a first voltage level being output by the first battery cell;
• a second voltage sensor being electrically coupled to the second battery cell, the second voltage sensor outputting a second signal indicating a second voltage level being output by the second battery cell;
• a third voltage sensor being electrically coupled to the third battery cell, the third voltage sensor outputting a third signal indicating a third voltage level being output by the third battery cell;
• a battery module voltage sensor being electrically coupled to the battery module, the battery module voltage sensor outputting a fourth signal indicating a battery module voltage level being output by the battery module;
• a microcontroller operably coupled to the first, second, and third voltage sensors, the battery module voltage sensor, and a memory device;
• the memory device having a battery module voltage out-of-range low error value corresponding to a square root of a first sum of squares value therein, the first sum of squares value corresponding to a sum of first, second, and third battery cell voltage measurement error square values and a battery module voltage measurement error square value;
• the microcontroller determines first, second, and third voltage values based on the first, second, and third signals, respectively;
• the microcontroller further determines a battery module voltage value based on the fourth signal;
• the microcontroller further determines if at least one of the first voltage value, the second voltage value, and the third voltage value is less than a desired minimum cell voltage value;
• the microcontroller further replaces at least one of the first voltage value, the second voltage value, and the third voltage value that is less than the desired minimum cell voltage value with a desired cell voltage value, the desired cell voltage value being greater than the desired minimum cell voltage value;
• the microcontroller further sums the first voltage value, the second voltage value, and the third voltage value to obtain a battery module low voltage sum value;
• and
• the microcontroller further generates a first control signal to induce a contactor to transition from a closed operational position to an open operational position to electrically decouple the battery module from an electrical load, if a difference between the battery module low voltage sum value and the battery module voltage value is greater than or equal to the battery module voltage out-of-range low error value indicating the voltage out-of-range low condition.

A system for determining a voltage out-of-range low condition of a battery module;

• the battery module having at least first, second, and third battery cells, comprising:
• a first voltage sensor being electrically coupled to the first battery cell, the first voltage sensor outputting a first signal indicating a first voltage level being output by the first battery cell;
• a second voltage sensor being electrically coupled to the second battery cell, the second voltage sensor outputting a second signal indicating a second voltage level being output by the second battery cell;
• a third voltage sensor being electrically coupled to the third battery cell, the third voltage sensor outputting a third signal indicating a third voltage level being output by the third battery cell;
• a battery module voltage sensor being electrically coupled to the battery module, the battery module voltage sensor outputting a fourth signal indicating a battery module voltage level being output by the battery module;
• a microcontroller operably coupled to the first, second, and third voltage sensors, the battery module voltage sensor, and a memory device;
• the memory device having a battery module voltage out-of-range low error value corresponding to a square root of a first sum of squares value therein, the first sum of squares value corresponding to a sum of first, second, and third battery cell weighted voltage measurement error square values and a battery module voltage measurement error square value;
• the microcontroller determines first, second, and third voltage values based on the first, second, and third signals, respectively;
• the microcontroller further determines a battery module voltage value based on the fourth signal;
• the microcontroller further determines if at least one of the first voltage value, the second voltage value, and the third voltage value is less than a desired minimum cell voltage value;
• the microcontroller further replaces the at least one of the first voltage value, the second voltage value, and the third voltage value that is less than the desired minimum cell voltage value with a desired cell voltage value, the desired cell voltage value being greater than the desired minimum cell voltage value;
• the microcontroller further sums the first voltage value, the second voltage value, and the third voltage value to obtain a battery module low voltage sum value;
• and
• the microcontroller further generates a first control signal to induce a contactor to transition from a closed operational position to an open operational position to electrically decouple the battery module from an electrical load, if a difference between the battery module low voltage sum value and the battery module voltage value is greater than or equal to the battery module voltage out-of-range low error value indicating the voltage out-of-range low condition.