Battery pack maintenance for electric vehicle

Abstract

A method and apparatus for repairing or testing a used battery pack from an electric vehicle include removing the battery pack from the vehicle. Battery tests are performed on at least some of the plurality of batteries and battery test results for each of the batteries tested are obtained. A cradle is configured to receive at least two different types of batteries. The cradle includes connectors to electrically couple circuitry of a battery tester to the battery.

1 . A method of repairing a used battery pack from an electric vehicle, comprising:
 removing the battery pack from the vehicle, the battery pack comprising a plurality of batteries;   performing battery tests on at least some of the plurality of batteries, obtaining a battery test result for the batteries tested and storing the battery test results in a database;   obtaining a plurality of replacement batteries;   performing battery tests on the plurality of replacement batteries, obtaining a test result the replacement batteries and storing the battery test results in the database;   retrieving the battery test results from the database; and   identifying batteries based upon the retrieved battery test results for use in forming a refurbished battery pack.   
     
     
         2 . The method of  claim 1  wherein the step of identifying batteries comprises applying selection criteria to the battery test results stored in the database. 
     
     
         3 . The method of  claim 2  wherein the selection criteria is based upon an adjustable parameter of the batteries, the method further including adjusting the adjustable parameter of at least one battery. 
     
     
         4 . The method of  claim 2  wherein the selection criteria is based upon an adjustable parameter of the batteries, wherein the selection criteria applies a lower weighting function to the adjustable parameter relative to a nonadjustable parameter. 
     
     
         5 . The method of  claim 2  wherein the selection criteria includes comparing parameters of batteries to each other and identifying parameters which are within a selected range. 
     
     
         6 . The method of  claim 2  wherein the selection criteria is based upon multiple parameters of the batteries. 
     
     
         7 . The method of  claim 1  including storing battery identification information in the database which is associated with a test result for a particular battery. 
     
     
         8 . The method of  claim 1  including implementing the database in a computer memory. 
     
     
         9 . The method of  claim 1  wherein the battery test comprise applying a forcing function to a battery and observing a result. 
     
     
         10 . The method of  claim 1  wherein the batteries comprise individual cells. 
     
     
         11 . The method of  claim 1  wherein the batteries comprise groups of cells. 
     
     
         12 . The method of  claim 1  wherein performing battery tests on the batteries in the battery pack is performed prior to removing the battery pack from the vehicle. 
     
     
         13 . The method of  claim 1  wherein performing battery tests on the batteries in the battery pack is performed subsequent to removing the battery pack from the vehicle. 
     
     
         14 . The method of  claim 1  wherein the replacement batteries are obtained from another battery pack. 
     
     
         15 . The method of  claim 1  wherein the replacement batteries comprise new batteries. 
     
     
         16 . The method of  claim 1  including identifying a configuration of batteries for placement in the refurbished battery pack based upon the battery test results. 
     
     
         17 . The method of  claim 1  including implementing the step of identifying in a computer. 
     
     
         18 . The method of  claim 1  including placing the battery pack in a cradle which is coupled to battery test circuitry. 
     
     
         19 . An apparatus for use in refurbishing a used battery pack from the electric vehicle, comprising:
 battery test circuitry configured to perform battery tests on batteries in the used battery pack;   a database configured to contain battery identification information and at least one associated battery parameter obtained from the battery test circuitry;   a selection criteria which identifies batteries for use in creating a refurbished battery pack; and   a controller configured to retrieve information from the database, apply the selection criteria and responsively provide selection information output which indicates which of the batteries identified in the database are suitable for use in creating a refurbished battery pack.   
     
     
         20 . The apparatus of  claim 19  wherein the selection criteria includes comparing parameters of batteries to each other and identifying parameters which are within a selected range. 
     
     
         21 . The apparatus of  claim 18  wherein the selection criteria is based upon an adjustable parameter of the batteries, the controller further configured to adjust the adjustable parameter of at least one battery. 
     
     
         22 . The apparatus of  claim 20  wherein the selection criteria is based upon an adjustable parameter of the batteries, wherein the selection criteria applies a lower weighting function to an adjustable parameter relative to a nonadjustable parameter. 
     
     
         23 . The apparatus of  claim 19  wherein the selection criteria is based upon multiple parameters of the batteries. 
     
     
         24 . The apparatus of  claim 19  wherein the database includes battery identification information associated with a test result for a particular battery. 
     
     
         25 . The apparatus of  claim 19  wherein the battery test comprises applying a forcing function to a battery and observing a result. 
     
     
         26 . The apparatus of  claim 19  wherein the batteries comprise individual cells. 
     
     
         27 . The apparatus of  claim 19  wherein the batteries comprise groups of cells. 
     
     
         28 . The apparatus of  claim 19  wherein the selection information output includes information identifying a configuration of batteries for placement in the refurbished battery pack based upon the battery test results. 
     
     
         29 . The apparatus of  claim 19  including a cradle coupled to the battery test circuitry configured to receive a battery and couple the battery to the battery test circuitry. 
     
     
         30 . The apparatus of  claim 29  including circuitry coupled to the cradle configured to select a polarity of an electrical connection to the battery. 
     
     
         31 . An apparatus for testing a battery of a battery pack from an electric vehicle, comprising:
 test circuitry configured to perform a battery test on the battery;   a cradle configured to receive the battery, the cradle comprising:
 first and second connectors configured to electrically connect the test circuitry to end connectors of the battery; and 
 a midpoint connector configured to electrically connect the test circuitry to an electrical midpoint between the end connectors. 
   
     
     
         32 . The apparatus of  claim 31  wherein the cradle includes a lock mechanism to secure the battery in the cradle. 
     
     
         33 . The apparatus of  claim 31  wherein the cradle includes a temperature sensor. 
     
     
         34 . The apparatus of  claim 31  wherein the midpoint connector includes a plurality of electrical connectors configured to couple to a plurality of electrical midpoints between the end connectors of the battery. 
     
     
         35 . The apparatus of  claim 31  including a second midpoint connector configured to couple to additional midpoint connections between the end connectors of the battery. 
     
     
         36 . The apparatus of  claim 35  wherein the midpoint connectors are positioned opposite one another. 
     
     
         37 . The apparatus of  claim 35  wherein the second midpoint connector is carried on a slidable portion. 
     
     
         38 . The apparatus of  claim 38  including a lock mechanism to secure the slidable portion to a base of the cradle. 
     
     
         39 . The apparatus of  claim 37  wherein the cradle includes a cover configured to cover the battery. 
     
     
         40 . The apparatus of  claim 39  wherein the cradle includes a switch actuated by the cover when the cover is in a closed position. 
     
     
         41 . The apparatus of  claim 31  wherein the test circuitry is configured to measure a dynamic parameter of the battery. 
     
     
         42 . The apparatus of  claim 31  including polarity switching circuitry configured to selectively switch polarity of the first and second connectors coupled to the test circuitry. 
     
     
         43 . The apparatus of  claim 34  including polarity switching circuitry configured to switch polarity of the electrical connectors coupled to the electrical midpoints. 
     
     
         44 . The apparatus of  claim 31  wherein the first and second connectors comprise Kelvin connections.