Battery management system

A battery management system, comprising:

• a programmed central processing unit;
• a plurality of battery modules in communication with said programmed central processing unit, each said battery module comprising:
• a rechargeable battery;
• a sensor node operably coupled to said rechargeable battery, said sensor node comprising:
• a temperature sensor operably coupled to said rechargeable battery and adapted to generate a battery temperature signal representative of a temperature of said rechargeable battery;
• a voltage sensor operably coupled to said rechargeable battery and adapted to generate a battery voltage signal representative of a voltage of said rechargeable battery;
• a memory adapted to store a plurality of battery status condition signals;
• and
• a programmed microcontroller in communication with said temperature sensor and said voltage sensor and operably coupled to said memory and adapted to process said rechargeable battery temperature signal and said rechargeable battery voltage signal to generate said plurality of battery status condition signals;
• a line driver optically coupled to said sensor node and adapted to transmit and receive signals between said programmed microcontroller and said programmed central processing unit;
• and
• a direct current charger operably coupled to said rechargeable battery and adapted to controllably provide a charging current to said rechargeable battery;
• and
• a bulk charger in communication with said programmed central processing unit and operably coupled to said rechargeable batteries and adapted to controllably provide a bulk charging current to all of said rechargeable batteries;
• wherein said rechargeable batteries are connected in series.

A battery management system comprising:

• a programmed central processing unit;
• a plurality of battery modules in communication with said programmed central processing unit, each said battery module comprising:
• a rechargeable battery;
• a sensor node operably coupled to said rechargeable battery, said sensor node comprising:
• a temperature sensor operably coupled to said rechargeable battery and adapted to generate a rechargeable battery temperature signal representative of a temperature of said rechargeable battery;
• a voltage sensor operably coupled to said rechargeable battery and adapted to generate a rechargeable battery voltage signal representative of a voltage of said rechargeable battery;
• a memory adapted to store a plurality of battery status conditions;
• a programmed microcontroller in communication with said temperature sensor, said voltage sensor, and said memory and adapted to process said rechargeable battery temperature signal and said rechargeable battery voltage signal to generate said plurality of battery status conditions;
• a line driver optically coupled to said sensor node and adapted to transmit and receive signals between said programmed microcontroller and said programmed central processing unit;
• and
• a DC/DC converter operably coupled to said rechargeable battery and adapted to controllably provide a charge current to said rechargeable battery;
• a bulk battery charger in communication with said programmed central processing unit and operably coupled to said rechargeable batteries and adapted to controllably provide a bulk charging current to said rechargeable batteries;
• a current sensor in communication with said programmed central processing unit and operably coupled to said bulk battery charger and adapted to generate a bulk charging current signal representative of a bulk charging current level;
• an auxiliary power supply operably coupled to each of said DC/DC converters and adapted to provide a DC power supply to each of said DC/DC converters;
• and
• a control switch operably coupled to said bulk battery charger and in communication with said programmed central processing unit and adapted to controllably interrupt said bulk charging current.

A battery management system, comprising:

• a programmed central processing unit;
• a plurality of battery modules in communication with said programmed central processing unit, each said battery module comprising:
• a rechargeable battery;
• a sensor node operably coupled to said rechargeable battery, said sensor node comprising:
• a plurality of battery condition sensors operably coupled to said rechargeable battery and adapted to generate a plurality of battery condition signals representative of a plurality of operating conditions of said rechargeable battery;
• and
• a programmed microcontroller in communication with said plurality of battery condition sensors and adapted to process said plurality of battery condition signals to generate a plurality of battery status signals representative of a plurality of status conditions of said rechargeable battery;
• and
• a direct current charger operably coupled to said rechargeable battery and adapted to controllably provide a charging current to said rechargeable battery;
• a bulk battery charger in communication with said programmed central processing unit and operably coupled to said rechargeable batteries and adapted to controllably provide a bulk charging current to all of said rechargeable batteries;
• a current sensor in communication with said programmed central processing unit and operably coupled to said bulk battery charger and adapted to generate a bulk charging current signal representative of a bulk charging current level;
• an auxiliary power supply operably coupled to each of said direct current chargers and adapted to provide a DC power supply to each of said direct current chargers;
• and
• a control switch operably coupled to said bulk battery charger and in communication with said programmed central processing unit and adapted to controllably interrupt said bulk charging current;
• wherein said rechargeable batteries are connected in series.

A battery module, comprising:

• a rechargeable battery;
• a sensor node operably coupled to said rechargeable battery, said sensor node comprising:
• a plurality of battery condition sensors operably coupled to said rechargeable battery and adapted to generate a plurality of battery condition signals representative of a plurality of operating conditions of said rechargeable battery;
• and
• a programmed microcontroller in communication with said plurality of battery condition sensors and adapted to process said plurality of battery condition signals to generate a plurality of battery status signals representative of a plurality of status conditions of said rechargeable battery, said plurality of battery status signals including:
• a high temperature flag signal indicating a temperature of said rechargeable battery is greater than a predetermined maximum temperature;
• a low temperature flag signal indicating said temperature of said rechargeable battery is less than a predetermined minimum temperature;
• a high voltage flag signal indicating a voltage of said rechargeable battery is greater than a predetermined clamping voltage;
• and
• a low voltage flag signal indicating said voltage of said rechargeable battery is less than a predetermined minimum voltage;
• and
• a direct current charger operably coupled to said rechargeable battery for controllably providing a charging current to said rechargeable battery.

A battery module, comprising:

• a rechargeable battery;
• a sensor node operably coupled to said rechargeable battery, said sensor node comprising:
• a temperature sensor operably coupled to said rechargeable battery and adapted to generate a battery temperature signal representative of a temperature of said rechargeable battery;
• a voltage sensor operably coupled to said rechargeable battery and adapted to generate a rechargeable battery voltage signal representative of a voltage of said rechargeable battery;
• a memory adapted to store a plurality of battery status conditions;
• a programmed microcontroller in communication with said temperature sensor, said voltage sensor, and said memory and adapted to process said battery temperature signal and said battery voltage signal to generate said plurality of battery status conditions, said plurality of battery status conditions including:
• a high temperature condition indicating a temperature of said rechargeable battery is greater than a predetermined maximum temperature;
• a low temperature condition indicating said temperature of said rechargeable battery is less than a predetermined minimum temperature;
• a high voltage condition indicating a voltage of said rechargeable battery is greater than a predetermined clamping voltage;
• and
• a low voltage condition indicating said voltage of said rechargeable battery is less than a predetermined minimum voltage;
• a line driver optically coupled to said programmed microcontroller and adapted to permit communication between said programmed microcontroller and an external programmed central processing unit;
• and
• a DC/DC converter operably coupled to said rechargeable battery and adapted to controllably provide a charging current to said rechargeable battery.

A method for charging and maintaining a plurality of rechargeable batteries connected in series in a full and ready condition comprising:

• measuring a temperature of each of said rechargeable batteries;
• measuring a voltage of each of said rechargeable batteries;
• providing a variable bulk charging current to all of said rechargeable batteries;
• and
• providing a separate charging current to each of said rechargeable batteries.

A method for charging and maintaining a plurality of rechargeable batteries connected in series in a full and ready condition comprising:

• measuring a temperature of each of said rechargeable batteries;
• measuring a voltage of each of said rechargeable batteries;
• providing a variable bulk charging current to all of said rechargeable batteries;
• reducing said variable bulk charging current when said measured voltage for any of said rechargeable batteries is greater than or equal to a predetermined battery clamping voltage level;
• providing a separate charging current to each rechargeable battery whose measured battery voltage is less than said battery clamping voltage level;
• and
• interrupting said bulk charging current when said bulk charging current is approximately equal to a predetermined lower bulk charging current level.

A method for charging and maintaining a plurality of rechargeable batteries connected in series in a full and ready condition comprising:

• measuring a temperature of each of said rechargeable batteries;
• measuring a voltage of each of said rechargeable batteries;
• providing a variable bulk charging current to all of said rechargeable batteries;
• reducing said variable bulk charging current when said measured voltage for any of said rechargeable batteries is greater than or equal to a predetermined battery clamping voltage level;
• providing a separate charging current to each rechargeable battery whose measured battery voltage is less than said battery clamping voltage level;
• interrupting said bulk charging current when said bulk charging current is approximately equal to a predetermined lower bulk charging current level;
• and
• providing a separate charging current to each rechargeable battery that is not full.

A method for charging and maintaining a plurality of rechargeable batteries connected in series in a full and ready condition comprising:

• measuring a temperature of each of said rechargeable batteries;
• measuring a voltage of each of said rechargeable batteries;
• providing a variable bulk charging current to all of said rechargeable batteries;
• reducing said variable bulk charging current when said measured voltage for any of said rechargeable batteries is greater than or equal to a predetermined battery clamping voltage level;
• providing a separate charging current to each rechargeable battery whose measured battery voltage is less than said battery clamping voltage level;
• interrupting said bulk charging current when said bulk charging current is approximately equal to a predetermined minimum bulk charging current;
• providing a separate charging current to each rechargeable battery that is not full;
• providing a separate charging current to each full rechargeable battery whose measured temperature is less than a predetermined minimum temperature at a full and ready condition;
• and
• providing a separate charging current to each full rechargeable battery whose measured battery voltage is less than a predetermined lower level at a full and ready condition.