Tesla's Battery Management System (BMS)

Improving the accuracy of estimating battery health in electric vehicles to provide more reliable and trustworthy battery state information to vehicle users. The technique involves using onboard sensors and vehicle data to estimate battery health indicators like range and energy retention without needing external equipment or laboratory tests. This allows more accessible and real-time battery health monitoring in the vehicle itself. The method leverages the existing battery management system (BMS) and vehicle sensors to analyze factors like voltage, current, temperature, and charge history to more accurately estimate battery health indicators. This provides a more reliable and trustworthy indication of battery state to vehicle users compared to traditional methods that rely on complex and time-consuming processes.

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A system for determining the state of health of an electric vehicle battery pack, comprising a battery management system (BMS) that estimates remaining capacity based on operating parameters, and a data analytics module that analyzes historical data from the BMS to provide a more accurate characterization of battery health and range estimation. The system enables remote monitoring and analysis of battery performance, providing consumers with a more reliable indication of battery health and range capability.

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A battery management system for electric vehicles and other applications that employs multi-channel, bi-directional signaling to improve performance and redundancy. The system uses a master-slave architecture where a host microcontroller communicates with multiple low-level battery management ICs that directly manage battery cells. Commands and responses travel in both clockwise and counterclockwise directions across a closed-loop transmission path that serially couples the ICs, providing redundant paths and improved fault tolerance.

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A battery management system for electric vehicles that employs a master/slave architecture with bi-directional signaling and redundant paths across multiple series-connected battery modules. The system features a host controller that communicates with low-level battery management ICs, which manage individual battery cells, through a closed-loop daisy chain loop. This architecture enables robust and dynamic management of battery cells, improving system performance and fault tolerance in the presence of mechanical vibration, temperature changes, and electrical interference.

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A battery service unit for high-voltage battery packs that enables energy management and maintenance without requiring installation into an operational electric vehicle. The unit includes independently powered charger and discharger components, an operating environment simulator, and a primary connection system to interface with the battery pack. It can automatically set desired state-of-charge levels, dissipate energy, and simulate vehicle operating conditions to enable safe and controlled charging and discharging of the battery pack in various scenarios, including storage, transportation, recycling, and service operations.

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A closed-loop battery management system for electric vehicles that provides bidirectional communication and redundant paths across multiple series-connected battery modules. The system employs a master-slave architecture with a host microcontroller that communicates with low-level battery management ICs, enabling commands and responses to be transmitted in either direction over a closed-loop transmission path. This architecture enhances system reliability and fault tolerance by providing multiple communication paths and redundant signaling capabilities.

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Battery management system that improves the performance and redundancy of the system. The system includes a multi-channel and bi-directional signaling procedures that improve the performance and redundancy of the system.

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A battery management system for electric vehicles and other applications that employs multi-channel, bidirectional signaling to improve performance and redundancy. The system uses a master-slave architecture where a host microcontroller communicates with multiple low-level battery management ICs that directly manage battery cells. Commands and responses travel in both clockwise and counterclockwise directions across a closed-loop transmission path that series-couples the ICs, enabling robust and dynamic management of battery cells.

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A closed-loop battery management system for electric vehicles and other applications that provides bi-directional communication and redundant paths between a central controller and multiple battery modules. The system enables robust management of battery cells in harsh environments, including vibration, temperature extremes, and multiple power domains, while ensuring reliable operation and fault tolerance.

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A multi-channel two-way battery management system that provides bidirectional signaling and redundant paths across multiple battery modules coupled in series, enabling robust and dynamic management of battery cells in electric vehicles and other applications with high performance requirements.

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A battery management system for electric vehicles that employs a closed-loop, bi-directional signaling architecture to manage battery cells. The system features a master-slave architecture where a host microcontroller communicates with multiple low-level battery management ICs that directly manage battery cells. The ICs are serially coupled in a closed-loop transmission path that enables commands and responses to travel in either direction, providing redundancy and improved system reliability.

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A closed loop signaling architecture for battery management systems that provides robustness and redundancy for battery packs used in applications like electric vehicles. The architecture uses a master-slave configuration with a central host communicating bi-directionally with multiple lower level battery management circuits. Signals can travel clockwise or counterclockwise around the closed loop formed by serially connecting the battery management circuits. This allows redundant paths and reduces interference compared to centralized signaling.

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External thermal conditioning system for electric vehicles that provides active cooling or heating of the vehicle's battery pack during charging to maintain optimal operating temperatures. The charging station detects the battery's thermal information and provides customized thermal conditioning through connections like fluid loops, air intakes, or contact pads. This allows external cooling during fast charging when internal systems can't keep up, or heating to bring the battery up to a required temperature. It enables more efficient and flexible charging by supplementing the onboard cooling system.

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An operational mode for electric vehicles that extends the life of the vehicle's battery pack. The mode involves adjusting charging, discharging, and temperature limits when the vehicle is parked for extended periods. When selected, the mode allows the battery to self-discharge deeper before charging, limits charging rates, and maintains a higher minimum charge level. This reduces cycling and stress on the battery when left connected to a charger. The mode also sets temperature limits and balancing during discharge.

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A battery service unit for high-voltage battery packs that enables energy management and maintenance without requiring installation in an operable electric vehicle. The unit provides a vehicle signature simulation circuit to replicate the operating environment, and multiple access mechanisms to charge or discharge the battery pack through its primary or secondary high-voltage ports. The unit can automatically set the desired state of charge (SOC) level and operate the battery pack outside the vehicle environment, making it suitable for scenarios such as storage, transportation, recycling, and repair.

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A system for managing high-voltage battery packs in electric vehicles through a secondary service port, enabling safe charging and discharging of the battery pack when the primary service connection is unavailable or compromised. The system includes a dedicated service port with direct access to the battery contactor, allowing for independent electrical connectivity and control of the battery pack's state of charge (SOC). The system also includes safety features such as in-line diodes, fuses, and thermal control to prevent overcharging and ensure safe operation. The secondary service port enables maintenance and management operations such as SOC determination, isolation testing, and discharge management, even when the battery pack is not installed in the vehicle or the vehicle's electrical system is compromised.

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Battery management system for high-voltage battery packs that enables safe operation without installation in operational vehicles. The system integrates a high-voltage charger and discharger with an environment simulator, enabling controlled charging and discharging of battery packs even when the vehicle is not operational. The system automatically sets optimal SOC levels for battery packs, including during storage, transportation, and recycling scenarios, ensuring reliable operation and safety.

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A system and method for managing high-voltage battery packs through a secondary service port, enabling safe charging and discharging operations independent of the primary vehicle interface. The system includes a battery service unit that connects to the battery pack through a dedicated service port, bypassing the vehicle's electrical system and safety interlocks. The unit provides a controlled environment for charging and discharging the battery pack to a desired state of charge, with features such as automatic SOC determination, variable voltage/current control, and protection against over/under voltage, temperature, and electrical faults. The system enables safe and efficient battery management in scenarios where the primary vehicle interface is unavailable or compromised, including storage, transportation, recycling, and service operations.

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Energy storage system for electric vehicles that enables controlled discharging through self-discharge mechanisms. The system integrates a battery pack with built-in safety features that automatically manage energy transfer between the battery and an external port. When the battery is installed in an operational vehicle, it can be charged or discharged through the vehicle's electrical connector. However, when the vehicle is not operational, the battery can be charged or discharged through an external port, utilizing the vehicle's electrical infrastructure. The system includes a self-discharge mechanism that initiates energy dissipation from the battery pack's internal components without requiring vehicle electrical connection. This enables safe discharging of the battery pack in situations where vehicle availability is uncertain.

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A battery service unit for maintaining and managing high-voltage battery packs in electric vehicles, enabling safe charging and discharging operations independent of the vehicle's operational status. The unit features a primary connection system, high-voltage discharger, and operating environment simulator, allowing for controlled energy transfer and SOC management without requiring the battery pack to be installed in a functioning vehicle.

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