Battery pack with battery management system

Abstract

The invention relates to a battery pack with a battery management system, wherein the battery management system has a voltage monitoring unit, which in particular comprises a Zener diode for monitoring the battery pack voltage, and a first activation unit for activating the battery pack, which can be manipulated by means of an operating element, and a second activation unit for activating the battery pack, which can be manipulated by means of a communication signal, wherein the battery management system is configured such that, upon detection of a battery pack voltage below a threshold value, the battery pack is placed in an unactivatable state. It is proposed that, in the unactivatable state, the battery management system is configured such that, depending on the first activation unit and the second activation unit, the battery pack is placed in a commissioning mode by means of manipulation of the first activation unit and / or by means of manipulation of the second activation unit.

Description

Technical Field

[0001] This invention relates to a battery pack with a battery management system, the battery management system having a voltage monitoring unit, which in particular includes a Zener diode for monitoring the battery pack voltage, and a first activation unit operable via an operating element for activating the battery pack, and a second activation unit operable via a communication signal for activating the battery pack. The battery management system is configured such that when the battery pack voltage is detected to be below a threshold, the battery pack is placed in an inactive state. The invention proposes that, in the inactive state, the battery management system is configured such that the battery pack, in relation to the first and second activation units, is placed into a debugging mode by operating the first activation unit and / or by operating the second activation unit. This advantageously ensures that the debugging mode can be initiated even in the inactive state. Background Technology

[0002] A battery pack with a battery management system is known, wherein the battery management system includes a voltage monitoring unit. Summary of the Invention

[0003] The battery pack is configured to supply energy to the power-consuming device. The battery pack is particularly configured as a replaceable battery pack. The power-consuming device can particularly be configured as a propulsion device, preferably an electric bicycle. In the context of this application, an electric bicycle should be understood particularly as a bicycle having a drive unit for assisting the rider. The electric bicycle is preferably configured as an E-Bike, Pedelec, S-Pedelec, cargo bicycle, folding bicycle, etc. The drive unit has a motor, which can be configured, for example, as a mid-drive motor or a hub motor. The motor is preferably configured as an electric motor. The drive unit is connected to the battery pack for supplying energy to the drive unit. The battery pack has a housing, which is preferably detachably connected to the housing of the power-consuming device, particularly to the frame of the electric bicycle. The electric bicycle preferably has a control unit, wherein the control unit of the electric bicycle is associated with electronic devices. The electronic devices of the electric bicycle preferably include sensor units, wherein the sensor units can, for example, include motion sensors, torque sensors, speed sensors, GNSS receivers, magnetic sensors, etc. Furthermore, the electronic devices particularly include at least one communication interface for wirelessly connecting the electric bicycle to mobile terminal devices and / or servers. The communication interface can be configured as a short-range communication interface, especially as a Bluetooth interface or a WiFi interface, for connecting to mobile terminal devices.

[0004] Alternatively, the power-consuming device can also be constructed as other lightweight electric vehicles, such as eScooter or electric motorcycle. Likewise, it is possible to consider constructing the power-consuming device as gardening tools, household appliances, or handheld machine tools.

[0005] The replaceable battery pack is preferably constructed in a tool-free, detachable manner with respect to the power-consuming device. Alternatively, the battery pack can also be fixedly mounted or integrated into the casing of the electric bicycle. Tool-free detachment here should also be understood as detachment via a lock, such as a bicycle lock. The lock here can be configured, for example, to be operable by a key or electric actuator. The battery pack is particularly configured to be connectable to a charging device for charging the battery pack. Alternatively or additionally, the battery pack can also be configured such that it is rechargeable while connected to the electric bicycle.

[0006] Preferably, the battery pack includes a housing. At least one battery cell is arranged within the housing of the battery pack. The housing of the battery pack is preferably constructed as an outer shell. The battery pack, particularly the housing, can be configured to be detachably or securely connected to a power-consuming device, particularly an electric bicycle and / or charging equipment, via a mechanical interface. The housing preferably has at least one housing component constructed as an outer shell component. Here, the outer shell component spaces the battery pack outwards and is accessible to the user.

[0007] The battery pack is configured to be electrically connected to a power-consuming device via an electrical interface. This electrical connection allows, for example, the battery pack to be charged and / or discharged. Alternatively or additionally, it may be considered that information can be transmitted from the battery pack to the power-consuming device and vice versa via the electrical interface. The power-consuming device or charger has an electrical interface corresponding to the electrical interface of the battery pack.

[0008] The electrical interface is preferably constructed as a contact interface, wherein the electrical connection is achieved through the physical contact of at least two conductive members. The electrical interface preferably includes at least two electrical contact elements. In particular, one of the electrical contact elements is constructed as a positive contact, and the other as a negative contact. Furthermore, the electrical interface may have at least one additional contact configured to transmit additional information to the electric bicycle and / or charging device. The additional contact may be configured as a signal contact, an encoded contact, a temperature contact, a bus contact, etc. The electrical contact element may, for example, be constructed as a spring contact element in the form of a contact tulip, or as a flat contact in the form of a contact blade. Alternatively or additionally, the electrical interface may have a secondary charging coil element for inductive charging. The mechanical interface and the electrical interface may be integrated together or constructed separately from each other.

[0009] In addition to the circuit board, the electronics of the battery pack may also include computing units, control units, transistors, capacitors, and / or storage units. Additionally or alternatively, information may be acquired by the electronics. The electronics are configured to control or regulate the battery pack and / or power-consuming devices. The electronics include a battery management system (BMS) configured to monitor the battery pack. The BMS is particularly configured to prevent overcharging and / or deep discharging of the battery pack. Preferably, the BMS is configured for proper cell balancing. The electronics may also have one or more sensor elements, such as temperature sensors for determining the temperature within the battery pack or motion sensors for determining motion. Alternatively or additionally, the electronics may have encoding elements, such as encoded resistors. In the context of this application, a circuit board should be understood as a circuit carrier having an organic or inorganic substrate, such as an IMS. The circuit board can be configured as a rigid circuit board or a flexible circuit board. Furthermore, the circuit board can be a component-equipped or component-free circuit board. The circuit board can be constructed in a single layer or multiple layers.

[0010] A battery cell can be constructed as an electrochemical cell having a structure in which one cell electrode is located at one end and the other cell electrode is located at the opposite end. In particular, the battery cell has a positive cell electrode at one end and a negative cell electrode at the opposite end. Preferably, the battery cell is constructed of NiCd or NiMn, and particularly preferably a lithium-based battery cell or a lithium-ion battery cell. Alternatively, for example, the battery cell can be constructed as a pouch cell or a prismatic cell. The battery pack voltage is typically a multiple of the voltage of a single battery cell and is determined by the connection method of the battery cells (parallel or series). In common battery cells with a voltage of 3.6V, exemplary battery pack voltages of 3.6V, 7.2V, 10.8V, 14.4V, 18V, 36V, 54V, 108V, etc., are thus obtained. Preferably, the battery cell is constructed as a cylindrical cell, at least substantially cylindrical, wherein the cell electrode is arranged at the cylindrical end.

[0011] The voltage monitoring unit is configured to detect the battery pack voltage. The voltage monitoring unit may include a Zener diode for detecting the battery pack voltage. Alternatively, other circuitry, such as a MOSFET or voltage comparator, may be considered. Another embodiment employs a dedicated voltage measurement IC, which provides integrated functionality for voltage measurement, monitoring, and digitization. The voltage monitoring unit may also include a filter, such as a low-pass filter, to suppress measurement noise and ensure stable voltage measurement.

[0012] In the active state, the battery pack can supply energy to power-consuming devices and discharge and / or charge them. In the inactive state, normal activation is not possible, and the battery pack does not supply energy to power-consuming devices and is also configured not to be rechargeable. Here, the inactive state is used for deep discharge protection.

[0013] The debug mode is configured such that, even in an inactive state, the battery pack can be analyzed and / or communicated with, for example, through the control of power-consuming devices or external devices, such as diagnostic devices.

[0014] Furthermore, it is proposed that the operating element be arranged on the outer side of the housing. This advantageously provides an easily accessible operating element. The operating element can be configured as, for example, a button, switch, or key. It is also conceivable that the operating element be configured as a touch-sensitive surface, such as a capacitive sensor surface, a resistive sensor surface, or a sensor surface operating based on surface acoustic waves. Additionally, the operating element can be implemented as a knob, slider, or joystick to enable, for example, stepless adjustment. Another embodiment provides that the operating element is configured as a combination of the above elements, such as a button with an integrated touch-sensitive surface. The arrangement of the operating element on the outer side of the housing can be, for example, on the side wall, top side, bottom side, or front side. The specific positioning of the operating element can be adapted to the corresponding application to ensure optimal ergonomics and user-friendliness. An advantageous configuration protects the operating element from accidental operation, for example, through recesses, covers, or special shapes within the housing.

[0015] Furthermore, it is proposed that the operating element be configured as a power status display operating element. Therefore, it is advantageous to control not only the first activation unit but also the power status display via the operating element. The power status display specifically includes at least one display element configured to display the power status. The power status is obtained here through the electronics of the battery pack. The display element can be configured, for example, as an LED, multi-color LED, OLED display, LCD display, or electronic ink display. Furthermore, it is conceivable that the display element be implemented as a segmented display, a matrix display, or a bar display. The display of the power status can be performed steplessly or in discrete levels.

[0016] Furthermore, it is proposed that communication signals can be provided via an external device connected to the battery pack via a cable connection. The external device can be configured, for example, as a diagnostic device in the form of a laptop computer with diagnostic software installed. The cable connection can be, for example, via a USB connection. Alternatively, the cable connection can be configured via a serial interface, such as RS-232, RS-485, or UART, an Ethernet connection, a FireWire connection, or a proprietary interface.

[0017] Furthermore, it is proposed that communication signals can be provided through power-consuming devices connected to the battery pack. For this purpose, the power-consuming devices have electrical interfaces corresponding to the electrical interfaces of the battery pack. Communication signals can be transmitted encrypted to improve security. The protocol used for communication signals can be a standardized protocol, such as CAN, MODBUS, or SPI, or a proprietary protocol.

[0018] Furthermore, it is proposed that communication signals can be provided by external devices connected to the battery pack via a wireless communication interface. Specifically, the wireless communication interface can be configured as a Bluetooth interface, a WLAN interface (e.g., according to IEEE 802.11a / b / g / n / ac / ax), a ZigBee interface, an NFC (Near Field Communication) interface, a LoRaWAN interface, a Sigfox interface, a mobile communication interface (e.g., 2G / 3G / 4G / 5G), or an ultra-wideband (UWB) based interface. To ensure the security of wireless communication, various security mechanisms can be implemented, such as encryption, authentication, and access control. The external device can be configured as a smartphone, tablet, laptop, desktop computer, or dedicated controller and has appropriate software for communicating with the battery pack.

[0019] Furthermore, it is proposed that the battery pack is placed in debug mode when the first activation unit and the second activation unit are operated simultaneously, or when the first activation unit and the second activation unit are operated briefly in succession (i.e., when the first activation unit is operated first and the second activation unit is operated shortly afterward). Advantageously, this ensures that the debug mode cannot be unintentionally accessed. Enhanced security against unintentional activation of the debug mode is ensured through a combination of two activation mechanisms: physically operating the operating element of the first activation unit and operating the second activation unit via communication signals. This is particularly relevant when the battery pack is used in safety-critical applications. Additionally, it can be configured that two activation conditions must be met within a defined time window to activate the debug mode. This time window can be, for example, in the range of milliseconds to seconds and is configurable. Alternatively, a specific activation order for the first and second activation units can be set. For example, the operating element can be operated first, followed by the communication signal, or vice versa. Another configuration requires another security mechanism, such as entering a password or PIN, after activation of the debug mode to access the debug mode's functions. Specific functions available in debug mode can also be limited to ensure the security of the battery pack. It can record the activation of debug mode so that subsequent analysis can be performed in case of failure.

[0020] Furthermore, it is proposed that the first and second activation units each have edge triggers and are configured such that the battery pack is placed in debug mode only upon a positive or negative transition. This advantageously further enhances safety against unintentional activation. Edge triggers prevent debug mode activation by a continuously acting signal or continuously operated button. Instead, a clear change in signal state, i.e., a positive or negative transition (edge), is required. The type of edge trigger (rising edge or falling edge) can be the same or different for the first and second activation units. An advantageous configuration is that the edge type is configurable. The edge triggers can be implemented by corresponding circuitry in the battery pack's electronics, for example, by a Schmitt trigger or an edge recognition circuit with an operational amplifier or comparator. Edge triggers also enable more complex activation sequences, where a specific combination of positive or negative transitions on the first and second activation units is required to activate debug mode. This further enhances safety against unintentional activation. Additionally, the duration of the edge signal can be monitored to prevent false triggering due to brief disturbances.

[0021] Furthermore, it is proposed to supply power to the battery management system in commissioning mode. This advantageously ensures comprehensive diagnosis and analysis of the battery pack even in fault conditions, especially during deep discharge. Power to the battery management system in commissioning mode can also be provided through a separate power supply circuit independent of the battery pack. This allows access to the battery management system and the execution of diagnostic measures even when the battery pack itself can no longer provide power. Alternatively, power to the battery management system in commissioning mode can be guaranteed by an emergency power supply within the battery pack, such as through a small capacitor or a single battery cell with a small capacity. Another possibility is to provide power to the battery management system in commissioning mode through an external device used to activate the commissioning mode. This can be done, for example, through the same cable connection or wireless interface used for communication signals. Various parameters of the battery pack, such as cell voltage, current, and temperature, can be monitored and analyzed in commissioning mode. The functionality of the battery management system itself can also be checked in commissioning mode. The obtained diagnostic data can be transmitted to the external device and analyzed and evaluated there. Power to the battery management system in commissioning mode can be turned on and off by a separate operating element or via communication signals to conserve energy.

[0022] Furthermore, the present invention relates to an electric bicycle having a battery pack as described above. Attached Figure Description

[0023] Further advantages are illustrated in the following figures. The figures, description, and claims contain a large number of combined features. Those skilled in the art will also consider these features individually and combine them into other meaningful combinations. The figures show: Figure 1 A perspective view of an electric bicycle having a battery pack according to the present invention; Figure 2 : Used according to Figure 1 A three-dimensional view of the battery pack of an electric bicycle; Figure 3 : Used according to Figure 2 A schematic diagram of the first wake-up mechanism of the battery pack; Figure 4 : Used according to Figure 2 A schematic diagram of the second wake-up mechanism of the battery pack. Detailed Implementation

[0024] Figure 1 A power-consuming device 10 having an energy supply device 100 in the form of a battery pack 102 is shown in a perspective view. The power-consuming device 10 is exemplary configured as an electrically driven forward device 12, especially an electric bicycle 14. The electric bicycle 14 can be configured, for example, as a Pedelec or E-Bike.

[0025] The electric bicycle 14 has a frame 18, or bicycle frame. Two wheels 20 are connected to the frame 18. Furthermore, the power-consuming device 10 has a drive unit 22, which includes an electric motor. The electric motor is preferably constructed as a permanent magnet driven brushless DC motor. The electric motor is exemplaryly constructed as a mid-drive motor, although hub motors and the like are also possible.

[0026] The drive unit 22 includes a control unit (not shown) configured to control or regulate the electric bicycle 14, particularly the electric motor. The electric bicycle 14 has pedal cranks 24. The pedal cranks 24 are connected to pedal crank shafts (not shown).

[0027] The control unit and the drive unit 22, which includes an electric motor and a pedal crankshaft, are arranged in a drive housing 26 connected to the frame. The drive motion of the electric motor is preferably transmitted to the pedal crankshaft via a transmission (not shown), wherein the degree of assistance of the drive unit 22 is controlled or adjusted by the control unit.

[0028] The electric bicycle 14 is electrically and mechanically connected to a battery pack 102 configured to supply energy to the drive unit 22. The battery pack 102 is exemplarily configured as a replaceable battery pack. The battery pack 102 is exemplarily fully received within the frame 18 of the electric bicycle 14 in the connected state. This connection can be achieved by axially pushing the battery pack 102 into the downtube of the frame 18 or by pivoting the battery pack 102 into the frame 18 from the side. Alternatively, the battery pack 102 can also be configured such that it can be secured to the outside of the frame 18.

[0029] Battery pack 102 Figure 2 The image is shown in a perspective view. The battery pack 102 has a housing 104 in which 20 individual battery cells (not shown) are exemplarily arranged. The housing 104 is exemplarily multi-piece constructed and has a tubular base 110, which is exemplarily constructed of metal. At the ends, the housing 104 has two end plates 108 configured as connecting plates 112 and each having at least one connecting element 116. The connecting element 116 is associated with a mechanical interface of the battery pack 102 configured for mechanically connecting the battery pack 102 to an electric bicycle 14. The connecting element 116 is exemplarily configured as a notch in the connecting plate 112 into which a corresponding connecting element (not shown) of the electric bicycle 14 can engage. The tubular base 110 also exemplarily has two longitudinal slots 105 on its sides, which may also be associated with the mechanical interface or, for example, used for connection to a cover.

[0030] In addition, the battery pack 102 has a power status display 106. The power status display 106 is connected to the electronics 150 of the battery pack 102, which are arranged in the housing 104 of the battery pack 102. The power status display 106 is exemplary configured to be operable by a user by pressing a button on the operating element 107.

[0031] Furthermore, the battery pack 102 includes an electrical interface 114 for electrically connecting the battery pack 102 to the electric bicycle 14. The electrical interface 114 is exemplarily configured as a socket 115. The electrical interface 114 exemplarily includes four electrical contact elements, wherein two electrical contact elements are configured as power contacts, and at least one electrical contact element is configured for exchanging information between the battery pack 102 and the electric bicycle 14.

[0032] The battery pack 102 also includes electronics 150 arranged within a housing 104 of the battery pack 102. Electronics 150 exemplarily includes a circuit board 152 extending along the housing 104. Multiple electronic components, such as microcontrollers and storage units, are arranged on the circuit board 152 and are associated with a battery management system 154. The battery management system 154 is configured to monitor the battery pack 102, particularly the individual battery cells. This includes monitoring the temperature of the battery pack 102 or individual battery cells, and monitoring the voltage of the battery pack and the voltage of each individual battery cell. The electronics 150 of the battery pack 102 are connected to the electronics or control unit of the electric bicycle 14 via an electrical interface 114. The battery management system 154 includes a first activation unit, a second activation unit, and a voltage monitoring unit 160.

[0033] exist Figure 3 The text is a mix of seemingly unrelated fragments and incomplete sentences, making it impossible to translate accurately. It appears to be a collection of Figure 2 A schematic diagram of the first wake-up mechanism of the battery pack. When the battery pack 102 is not used, especially if it is not charged or discharged, or is disconnected from the power-consuming device 10, the battery pack is deactivated or placed in sleep mode, thereby advantageously saving energy. Therefore, in order to use the battery pack 102, it needs to be activated through a so-called wake-up process.

[0034] The battery pack 102, and especially the battery management system 154 of the battery pack 102, is configured such that it can be awakened or activated by a first activation unit by means of an operating element 107 on the housing 104 of the battery pack 102, or by means of a second activation unit by means of providing a communication signal 206.

[0035] Here, when the operating element 107 is manipulated 200 and the actual battery pack voltage is found to be higher than a threshold in step 202, the battery management system 154 activates power supply. The actual battery pack voltage is detected by the voltage monitoring unit 160. The threshold is selected such that sufficient battery pack voltage is ensured for the safe operation of the power-consuming device. If the actual battery pack voltage is lower than the threshold, power supply is not activated to prevent deep discharge of the battery pack 102 and protect the individual battery cells. In the illustrated embodiment, the activation of the operating element 107 and the determination of the actual battery pack voltage 202 are exemplary performed in parallel. Alternatively, these steps can also be performed sequentially. The specific value of the threshold can be adapted to the specific requirements of the application and the characteristics of the battery pack 102. The threshold can be fixedly stored or programmable. An advantageous configuration adjusts the threshold according to temperature to account for the effect of temperature on the battery pack voltage.

[0036] Similarly, when communication signal 206 is provided via power-consuming device 10 and the actual battery pack voltage is determined to be higher than a threshold in step 208, battery management system 154 activates power supply. For example, this is provided via the electrical interface of battery pack 102 when battery pack 102 is connected to electric bicycle 14. This connection may be made via a CAN bus, for example. Queries can be performed in parallel or sequentially.

[0037] If the actual battery pack voltage is below a threshold, the battery pack 102 is placed in an inactive state. In the inactive state, the battery pack 102 cannot be activated normally by the operating element 107 or the communication signal 206 as described above. This advantageously ensures that the power-consuming device 10 does not cause the battery pack 102 to continue discharging, which could lead to deep discharge.

[0038] However, in this protected mode, the battery pack 102 can be placed in a debug mode. For this, the manipulation 200 of the operating elements 107 of the battery pack 102 and the provision of communication signals 206 must be performed substantially simultaneously, as checked in method step 210. In this context, "simultaneously" can also be understood as the signal immediately following. In debug mode, diagnostic data can be read, parameters checked, and errors may be analyzed.

[0039] exist Figure 4 The text is a mix of seemingly unrelated fragments and incomplete sentences, making it impossible to translate accurately. It appears to be a collection of Figure 2 A schematic diagram of the second wake-up mechanism for the battery pack. Similar to the previous mechanism, this mechanism is also used to move the battery pack 102 from an inactive state to a commissioning mode, but employs a different approach. Here, when the battery pack 102 is not used to save energy and avoid deep discharge, it is deactivated or placed in sleep mode. Activation is performed via a "wake-up" signal.

[0040] The battery pack 102, and especially the battery management system (BMS) 154, is designed to be activated by two activation units: the first activation unit is triggered by manipulation 200a of the operating element 107 on the housing 104, and the second activation unit is triggered by providing a communication signal 204a.

[0041] However, with Figure 3 Conversely, the second wake-up mechanism uses an edge-triggered trigger. This means that not only the confirmation 200a of the operating element but also the communication signal 204a are considered only during signal state transitions, i.e., during positive or negative transitions. Continuously applied signals, such as pressed buttons or permanent communication signals, will not trigger any activation.

[0042] The signals of the two activation units are connected via an OR-logic gate 202a. This means that it is sufficient to detect an edge at either the operating element 200a or the communication signal 204a. If this is the case and the battery pack voltage is simultaneously below a threshold, the module used to power the BMS is activated 206a, and the battery pack 102 is placed in debug mode. Alternatively, it can be set according to the previous... Figure 3 In one embodiment, the two signals are connected by an AND-OR logic gate and therefore must have positive or negative transitions simultaneously or briefly in succession as edge triggers.

[0043] The advantage of this edge-based wake-up mechanism is that it improves safety compared to accidental triggering caused by button jamming or continuous signals. It provides precise control over debug mode and prevents unwanted activation.

Claims

1. A battery pack having a battery management system (154), wherein, The battery management system (154) includes: A voltage monitoring unit (160), wherein the voltage monitoring unit (160) particularly includes a Zener diode for monitoring the voltage of a battery pack; A first activation unit for activating the battery pack (102), the first activation unit being operable by an operating element (107); and The second activation unit is used to activate the battery pack (102), and the second activation unit can be controlled by communication signals. The battery management system (154) is configured such that when the battery pack voltage is detected to be below a threshold, the battery pack (102) is placed in an inactive state. Its features are, The battery management system (154) is configured in the inactive state such that the battery pack (102) is placed in a debug mode in relation to the first activation unit and the second activation unit by manipulating the first activation unit and / or by manipulating the second activation unit.

2. The battery pack according to claim 1, characterized in that, The battery pack (102) has a housing (104) wherein the operating element (107) is arranged on the outside of the housing (102).

3. The battery pack according to claim 2, characterized in that, The operating element (107) is configured as a power status display operating element (106).

4. The battery pack according to any one of the preceding claims, characterized in that, The communication signal (206) can be provided by an external device that is connected to the battery pack (102) via a cable connection.

5. The battery pack according to any one of the preceding claims, characterized in that, The communication signal (206) can be provided by a power-consuming device (10) connected to the battery pack (102).

6. The battery pack according to any one of the preceding claims, characterized in that, The communication signal (206) can be provided by an external device that is connected to the battery pack (102) via a wireless communication interface.

7. The battery pack according to claim 1, characterized in that, The battery management system (154) is configured such that when the first activation unit and the second activation unit are operated simultaneously or briefly in succession, the battery pack (102) is placed in the debugging mode.

8. The battery pack according to any one of the preceding claims, wherein, The first activation unit and the second activation unit each have an edge trigger and are configured such that the battery pack (102) is only placed in the debugging mode when there is a positive or negative transition.

9. The battery pack according to any one of the preceding claims, characterized in that, The battery management system (154) is supplied with energy in the commissioning mode.

10. An electric bicycle having a battery pack (102) according to any one of the preceding claims.

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