Modular battery system

Abstract

The invention relates to a modular battery system, comprising a battery module, in which at least two battery interfaces are formed, each battery interface being designed to electrically and mechanically connect to an exchangeable battery pack, the battery module having a DC-DC converter for each battery interface, the DC-DC converter being designed to electrically and mechanically connect to the exchangeable battery pack, the DC-DC converter being designed to electrically and mechanically connect to the exchangeable battery pack, the DC-DC converter being designed to electrically and mechanically connect to the exchangeable battery pack. Wherein the battery module has a busbar which is electrically connected to each DC voltage converter, and wherein the battery module has at least one electrical connection which is electrically connected to the busbar and which is designed to be connected to a load and a charging device, and wherein all DC voltage converters are designed to regulate the current of the respective battery interface separately from one another.

Description

Technical Field

[0001] The present invention relates to a modular battery system. Background Art

[0002] Battery systems are known for loads such as, for example, hand tools, gardening tools, etc. Such battery systems often use replaceable battery packs for power supply, which can be removed from the load and replaced. Replaceable battery packs can be used, for example, for different loads. Replaceability often only occurs within various battery systems that are geometrically and electrically compatible with each other. For example, different voltage levels are often divided here, such as 12V systems and 18V systems. In addition, the following loads are known, which do not allow battery operation but can only be operated by wired power supply. Summary of the Invention

[0003] In contrast, the modular battery system according to the invention with the features of claim 1 is characterized by particularly high flexibility. In particular, it is possible to simply and by means of a simple system supply electrical energy jointly by means of a plurality of different replaceable battery packs. In addition, it is possible to simply provide a particularly high electrical energy. This is achieved according to the invention by a modular battery system which comprises a battery module in which at least two battery interfaces are configured. Each battery interface is hereby respectively set up for electrical and mechanical connection to a replaceable battery pack. The battery module hereby has a DC voltage converter for each battery interface respectively. In addition, the battery module has a busbar which is electrically connected to each DC voltage converter. In addition, the battery module has at least one electrical connector which is electrically connected to the busbar. The electrical connector is hereby set up for connection to a load and / or to a charging device. All DC voltage converters are set up to respectively regulate the current of the corresponding battery interface separately from each other.

[0004] The element which can be particularly manipulated as an integral component is regarded as the battery module.

[0005] The common main wire is regarded as the busbar in particular, which common main wire can also be referred to as the common power bus, for example. The busbar can be configured, for example, as a physical busbar or alternatively by means of a laid cable or printed conductor on a circuit board.

[0006] The electrical connector can be configured in various ways, for example as a connecting element which can be connected to a plug and / or to a socket.

[0007] In other words, a modular battery system is provided, which includes battery modules that can be coupled to a plurality of replaceable battery packs. The replaceable battery packs can hereby supply the electrical energy stored therein at at least one electrical connection point by means of the battery modules. Additionally, the replaceable battery packs can be charged jointly via at least one electrical connection point of the battery modules. Here, a separate DC voltage converter is provided for each battery interface, and each replaceable battery pack can be connected to the battery interface. Hereby, the current can be adjusted individually for the respective battery interface by means of the DC voltage converter, and the current is transmitted from the battery interface to the busbar or vice versa.

[0008] The modular battery system hereby offers the advantage that a plurality of replaceable battery packs can be combined with each other particularly advantageously. Thereby, for example, the electrical capacities of a plurality of replaceable battery packs can be utilized jointly in order to be able to operate a load in a particularly simple and comfortable manner over a particularly long operating time range. Additionally preferably, the power of a plurality of replaceable battery packs can be combined by their combination, so that for example a particularly powerful load can be achieved using simple replaceable battery packs. Furthermore, the electrical energy stored in the replaceable battery packs can be provided in a particularly flexible manner and for a large number of different loads, in such a way that: for example, the compatibility of the electrical interfaces can be increased significantly by means of the battery modules. Additionally, different types of replaceable battery packs can be used jointly. Here, by the individual adjustment of the current between the battery interface and the busbar, replaceable battery packs with different voltage levels can be combined with each other, wherein for example the energy of all replaceable battery packs can be provided particularly effectively at a common electrical connection point. Additionally, replaceable battery packs with different states of charge, temperatures, etc. can be utilized particularly effectively with each other, while for example the power limitations of the replaceable battery packs do not negatively affect the overall system.

[0009] The current of each battery interface can be adjusted independently and flexibly by means of a separate DC voltage converter, whereby the potential of the electrical energy stored in the entire battery module can be utilized particularly effectively. Thus, for example, the power deficit of the individual replaceable battery packs can be compensated by other replaceable battery packs. Thereby, the operation of the replaceable battery packs can be coordinated with each other in such a way that operation with the required electrical power can be achieved over a particularly long period of time. Additionally, conversely, optimized charging for each replaceable battery pack can be achieved individually, for example with a specifically adjusted charging current.

[0010] Preferred refinements of the invention are the subject matter of the dependent claims.

[0011] Preferably, each DC voltage converter has a separate control unit, which is configured to regulate the current of the corresponding DC voltage converter. That is to say, for each DC voltage converter, its own control unit for operating it is provided. In particular, the control unit can include a microcontroller. Thereby, the regulation of the current flowing to or from the battery interface can be adjusted particularly flexibly and specifically.

[0012] In addition, for example, the control unit can be configured to decouple a fully discharged replaceable battery pack from the operation, so that the continued operation can be achieved by means of the remaining replaceable battery packs.

[0013] Particularly preferably, exactly one of the multiple control units is configured to form a main control unit. The main control unit is configured to control all other control units and in particular its own DC voltage converter. That is to say, exactly one of the multiple control units individually prescribes the current regulation algorithm for all other control units. Preferably, the main control unit is configured to communicate bidirectionally with all other control units. Thereby, electrical energy can be optimally provided by all battery interfaces in a particularly simple and effective manner.

[0014] Preferably, the battery module is configured to define the main control unit through the start-up process of the modular battery system. Particularly preferably, the battery module is configured to define the following control unit as the main control unit, which starts first, that is, obtains current flow first, when the battery system starts to operate. As an alternative, preferably a pre-defined control unit is determined as the main control unit. Thereby, the operation of the battery system can be implemented particularly easily and effectively.

[0015] In addition, preferably, the modular battery system further includes an additional main control unit, which is configured to control all control units. In this case, the additional main control unit is provided as an additional separate control unit relative to the control units coupled to the DC voltage converters. Thereby, the regulation of the current can be carried out centrally.

[0016] The preferred main control unit is configured to control the control unit such that the current flow is regulated based on at least one or more of the following parameters: the total operating time of the battery module, the service life of one or more of the replaceable battery packs in the replaceable battery pack, the available electrical energy of one or more of the replaceable battery packs in the replaceable battery pack, the charging time. In consideration of the respective capacities of all the connected replaceable battery packs, in particular the calculated duration of the possible energy supply of the entire battery module is regarded as the total operating time. That is to say, the operation of the battery module is carried out such that an optimal evenly distributed load is generated for all the replaceable battery packs, as seen from the respective states of the replaceable battery packs. Here, for example, a more powerful replaceable battery pack and / or a replaceable battery pack with a higher state of charge is subjected to a greater load than a less powerful replaceable battery pack and / or a replaceable battery pack with a lower state of charge. Thereby, a particularly high operating time of the battery module can be achieved with maximum power output.

[0017] Preferably, all the DC voltage converters are connected in parallel with the busbar and in particular are thereby also connected in parallel with each other. Thereby, all the DC voltage converters share the same voltage, whereby a particularly flexible and also particularly efficient operation of the modular operating system can be carried out.

[0018] Preferably, the DC voltage converters are each configured as unisolated DC voltage converters. That is to say, the input side and the output side of each DC voltage converter are not separated from each other, for example, by electrical isolation. Thereby, a particularly compact, efficient and cost-effective structure of the modular battery system can be achieved.

[0019] Particularly preferably, the modular battery system further includes a user interface, which in particular includes a display unit and / or an input unit. In particular, the user interface is connected to the control unit, particularly preferably to the main control unit. Preferably, the display unit can include one or more LEDs and / or a display. The input unit can include, for example, a keyboard for, for example, being able to turn on and / or turn off the modular battery system by manual key presses.

[0020] Furthermore, preferably, the battery module is configured to provide a DC voltage of at least 25 V, in particular a maximum of 60 V, preferably at least 40 V, preferably a maximum of 50 V. Thereby, a particularly efficient operation can be achieved for many applications.

[0021] Particularly preferably, the modular battery system includes at least two replaceable battery packs having the same battery voltage or different battery voltages. In particular, this enables any replaceable battery packs to be combined with each other and integrated into the modular battery system for jointly providing electrical energy, i.e., operating as a common energy storage device. Furthermore, preferably, electrical energy can be centrally supplied to a plurality of, in particular, at least partially different replaceable battery packs in the battery module for charging, where each replaceable battery pack can be optimally charged individually.

[0022] Particularly preferably, the battery module further includes a cooling mechanism which is preferably configured to cool the battery interface and / or the DC voltage converter. Preferably, the cooling mechanism is additionally configured to cool the busbar and / or the electrical connector. Thereby, effective operation can also be achieved permanently with high power.

[0023] Particularly preferably, the electrical connector additionally includes a mechanical interface which is configured to connect to a load and a charging device. That is to say, for example, one of the electrical connectors can be configured as a combination of an electrical and a mechanical interface for directly connecting a load or a charging device having a corresponding interface to the battery module. Thereby, particularly effective operation of a load having high power requirements, for example, can be achieved in a simple and robust manner.

[0024] Preferably, the modular battery system includes an inverter for providing an alternating voltage at at least one electrical connector. Preferably, the inverter is configured to provide an alternating voltage of at least 120V, in particular, a maximum of 240V. In other words, the inverter is preferably configured to provide a grid voltage. In particular, the inverter can be arranged between the electrical connector and the busbar. For example, the inverter can be part of the battery module. As an alternative, preferably, the rectifier can be separate from the battery module, where the battery modules are connected, for example, when needed. Preferably, the inverter can be reversible. Thereby, the inverter can provide a power supply voltage or be used as a charging device when an external alternating voltage is available, for example, through a socket. Thereby, particularly advantageous modularity can be provided. Thereby, power supply to a load provided for powering the grid can be easily and comfortably achieved with the help of the battery module.

[0025] Preferably, at least one electrical connector of the battery module and / or the inverter is configured as a socket. Preferably, a domestic socket is regarded as a socket which is, for example, configured to connect to a common domestic electrical grid plug. Thereby, operation of a load provided for powering the grid can be achieved with the help of the battery module in a particularly simple and comfortable manner.

[0026] Preferably, all the battery interfaces of the battery module are configured identically. That is to say, it is possible to use a plurality of replaceable battery packs having the same structure. As an alternative, preferably, at least two battery interfaces of the battery module can be configured differently in order to connect to different replaceable battery packs.

[0027] Particularly preferably, the modular battery system further includes a load, such as, for example, a power tool. Here, the battery module is configured as part of the load. In other words, the battery module is an essential component for the constitution of the whole load. That is to say, a system having a plurality of battery interfaces and a DC voltage converter for each battery interface is directly integrated into the load. Thereby, the system can be particularly easily and effectively directly integrated into the load and powered for modular energy supply. Description of the Drawings

[0028] The present invention will be described below with reference to embodiments in conjunction with the drawings. In the drawings, components having the same function are denoted by the same reference numerals. Herein:

[0029] Figure 1 A perspective view showing details of a modular battery system according to a first embodiment of the present invention;

[0030] Figure 2 A simplified schematic detail view showing a modular operating system of the first embodiment;

[0031] Figure 3 Another simplified schematic detail view showing a modular operating system of the first embodiment;

[0032] Figure 4 A perspective view showing the modular battery system of the first embodiment in the application of an AC generator; and

[0033] Figure 5 A simplified schematic detail view showing a modular operating system according to a second embodiment of the present invention. Detailed Description of the Invention

[0034] Figure 1 A perspective view showing details of a modular battery system 10 according to a first embodiment of the present invention. Figures 2 to 4 Shows Figure 1 Details of the modular battery system 10.

[0035] The modular battery system 10 includes a battery module 1, in which four battery interfaces 2 are configured in the shown preferred embodiment.

[0036] The battery module 1 is preferably configured as an element that can be manipulated as an integral component. Preferably, the battery module 1 can have an integral base body in which a battery interface 2 is configured.

[0037] Each battery interface 2 has an electrical interface and a mechanical interface respectively. By means of the electrical interface and the mechanical interface, the corresponding battery interface 2 can be electrically or mechanically connected to the replaceable battery pack 50. Preferably, the mechanical interface can include a busbar guide and / or a locking mechanism in order to be able to establish a particularly simple and cost-effective connection between the replaceable battery pack 50 and the battery module 1.

[0038] This connectability of the battery interface 2 to the replaceable battery pack 50 is configured to be releasable here. Thereby, the replaceable battery pack 50 can be flexibly connected to the battery module 1 and separated from it. For example, an easy replacement of the replaceable battery pack 50 can be carried out thereby. In addition, the total number of replaceable battery packs 50 connected to the battery module 1 can be flexibly adjusted in a simple manner thereby.

[0039] As the replaceable battery pack 50, in the illustrated embodiment, a replaceable battery pack for a load 51, such as a hand-held power tool, can preferably be used here. Here, the replaceable battery pack 50 can be connected to the battery module 1, and all of the replaceable battery packs have the same battery voltage or, as an alternative, at least partially have different battery voltages.

[0040] The battery module 1 includes a DC voltage converter 5 for each battery interface 2 here (see Figure 2 ).

[0041] The battery module 1 has a common busbar 3 here, and all DC voltage converters 5 are directly electrically connected to the busbar. The busbar 3 is preferably a conductive element, such as a wire element made of copper. In particular, the busbar 3 can also be referred to as a power bus.

[0042] Each DC voltage converter 5 is arranged between the corresponding battery interface 2 and the common busbar 3 here and connects them to each other. All DC voltage converters 5 are electrically connected in parallel with each other by means of the busbar 3 here.

[0043] The DC voltage converter 5 is configured here to convert the corresponding battery voltage on the battery interface 2 side into a common connection voltage on the busbar 3 side. Preferably, the connection voltage is greater than each battery voltage. That is, all individual voltages of the replaceable battery pack 50 are converted to the common connection voltage of the busbar 3 by means of the DC voltage converter 5 or vice versa.

[0044] A separate DC voltage converter 5 is provided for each connected replaceable battery pack 50, whereby particularly flexible regulation of the transfer of electrical energy between the individual replaceable battery packs 50 and the common bus bar 3 can be achieved. Thereby, replaceable battery packs 50 with different battery voltages can be used to jointly and collectively provide an electrical energy storage device with the capacity of all replaceable battery packs 50, wherein the potential of each replaceable battery pack 50 can be fully utilized optimally through the possibility of regulating the individual currents. In addition, it can be prevented hereby that, for example, a completely discharged or damaged replaceable battery pack 50 or an empty battery interface 2 may limit the power output of the entire battery module 1.

[0045] To regulate the current provided by means of the DC voltage converter 5, each DC voltage converter 5 respectively includes a separate control unit 55, wherein all control units 55 are connected to each other for combined and coordinated operation (see Figure 3 ). In particular, the control unit 55 can respectively manipulate a switch 56, which can open or close the current transfer.

[0046] Each DC voltage converter 5 with the corresponding control unit 55 can be arranged on a separate circuit board 57 here.

[0047] The battery module 1 includes an additional circuit board 57a here, on which an additional main control unit 55a is arranged. The main control unit 55a is connected to each of the other control units 55 here and is set up to control all these other control units 55. Here, the main control unit 55a prescribes for all other control units 55 which current should be provided to the corresponding battery interface and / or which current should be provided by the corresponding battery interface 2.

[0048] Here, the main control unit 55a regulates the control unit 55 depending on at least one or more of the following parameters: the total operating time of the entire battery module 1, the service life of one or more of the replaceable battery packs 50, the available electrical energy of one or more of the replaceable battery packs 50, in particular the charging time of the entire battery module 1. That is to say, the main control unit 55a can individually regulate the current by controlling the individual control units 55 so as to achieve the best efficiency of the entire battery module 1 and each individual replaceable battery pack 50.

[0049] The user interface 7 includes a display unit 71 and an input unit 72. The display unit 71 can for example have one or more LEDs and / or displays, by means of which the charge state of the battery module 1 and / or of the individual rechargeable battery packs 50 can be displayed. The input unit 72 can preferably include a keyboard, by means of which the user can for example switch on and switch off the battery module 1.

[0050] Furthermore, the battery module 1 includes an electrical connector 4. The electrical connector 4 is directly connected to the busbar 3 and is provided for a direct or indirect electrical and mechanical connection to the load 51 and the charging device 52.

[0051] Furthermore, the battery module 1 can have a cooling mechanism 40, which is provided for cooling the battery interface 2 (see Figure 1 ). The cooling mechanism 40 can for example produce a cooling effect by means of liquid cooling and / or air cooling. Thereby, a particularly efficient operation of the modular battery system 10 and the avoidance of overheating can be achieved.

[0052] The modular battery system 10 is suitable here for a wide variety of applications for providing electrical energy. Figure 4 A perspective view of the modular battery system 10 in the application in an alternator is shown here. Here, exactly two electrical connectors 4 are provided and they are configured as sockets, which are in particular provided for connection to a common household electrical grid plug.

[0053] The modular battery system 10 also includes an inverter here, which is provided for converting the DC voltage of the rechargeable battery pack 50 into an AC voltage of preferably at least 120 V and preferably at most 240 V. The AC voltage is provided here at the electrical connector 4. Thereby, the load 51 provided for powering the electrical grid can be operated by means of the modular battery system 10.

[0054] Furthermore, Figure 4 The connection of the modular battery system 10 to the charging device 52 is shown by way of example, which can advantageously provide a supply voltage by means of the use of the inverter 5 in order to charge the rechargeable battery pack 50.

[0055] In the application of the modular battery system 10 shown as an alternator in Figure 4 , the battery system 10 also includes a housing 20 with a frame 21. The frame 21 preferably forms a machine frame here, which encloses the receiving chamber 22. The battery module 1 of the modular battery system 10 and preferably other components are completely arranged inside the receiving chamber 22 here. The frame 21 provides good accessibility to the battery module 1 and its components here, which makes the operability easier and furthermore improves the air circulation and thus the cooling of the battery module 1.

[0056] The housing 20 with the frame 21 is configured here in such a way that a releasable fixing of the battery module 1 inside the receiving chamber 22 can be achieved. Thereby, the battery module 1 can be removed and, for example, the entire battery module 1 and / or the individual replaceable battery packs 50 can be replaced.

[0057] Figure 5 A simplified schematic detail view of a modular battery system 10 according to a second embodiment of the invention is shown. The second embodiment basically corresponds to Figures 1 to 4 the first embodiment, with the difference being an alternative design of the main control unit 55a. In Figure 5 the second embodiment, no additional separate main control unit 55a is provided, but rather one of the control units 55 of the DC voltage converter 5 forms the main control unit 55a. Thereby, a particularly simple and cost-effective structure of the modular battery system 10 can be achieved.

[0058] In the second embodiment, the main control unit 55a can hereby be predefined in a generally defined manner. As an alternative, the main control unit 55a can preferably be defined as one of the existing control units 55 each time the modular battery system 10 is started. For example, the control unit 55 that is started first, i.e., powered, can hereby be defined as the main control unit 55a.

Claims

1. A modular battery system, comprising: - a battery module (1), in which at least two battery interfaces (2) are constructed, - wherein each battery interface (2) is provided for electrical and mechanical connection with a replaceable battery pack (50), - wherein the battery module (1) has a DC voltage converter (5) for each battery interface (2) respectively, - wherein the battery module has a busbar (3) electrically connected to each DC voltage converter (5), and - wherein the battery module (1) has at least one electrical connector (4), which is electrically connected to the busbar (3) and is provided for connection with a load (51) and a charging device (52), and - wherein all DC voltage converters (5) are provided for separately regulating the current of the corresponding battery interface (2) respectively.

2. The modular battery system according to claim 1, wherein each DC voltage converter (5) has a separate control unit (55), and the control unit is provided for regulating the current of the DC voltage converter (5).

3. The modular battery system according to claim 2, wherein exactly one of the plurality of control units (55) is provided as a main control unit (55a) for controlling all other control units (55).

4. The modular battery system according to claim 3, wherein the battery module (1) is provided for defining the main control unit (55a), in particular the first control unit (55) to be started, through the start-up process of the modular battery system (10), or wherein the main control unit (55a) is pre-defined.

5. The modular battery system according to claim 2, further comprising an additional main control unit (55a), which is provided for controlling all control units (55).

6. The modular battery system according to any one of claims 3 to 5, wherein the main control unit (55a) is provided for controlling the control units so as to regulate the current flow based on at least one or more of the following parameters: the total operating time of the battery module (1), the service life of one or more of the replaceable battery packs in the replaceable battery pack (50), the available electrical energy of one or more of the replaceable battery packs in the replaceable battery pack (50), the charging time.

7. The modular battery system according to any one of the preceding claims, wherein all DC voltage converters (5) are electrically connected in parallel to the busbar (3).

8. A modular battery system, wherein the DC voltage converters (5) are respectively constructed as non-isolated DC voltage converters.

9. The modular battery system according to any one of the preceding claims, further comprising a user interface (7), and the user interface particularly includes a display unit (71) and / or an input unit (72).

10. The modular battery system according to any one of the preceding claims, wherein the battery module (1) is configured to provide a DC voltage of at least 25 V, in particular at most 60 V, preferably at least 40 V, preferably at most 50 V.

11. The modular battery system according to any one of the preceding claims, comprising at least two replaceable battery packs (50), the replaceable battery packs having the same or different battery voltages.

12. The modular battery system according to any one of the preceding claims, further comprising a cooling mechanism (40).

13. The modular battery system according to any one of the preceding claims, wherein the electrical connector (4) additionally has a mechanical interface for connection to a load (51) and a charging device (52).

14. The modular battery system according to any one of the preceding claims, further comprising a load (51), wherein the battery module (1) is configured as part of the load (51).

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