High-voltage storage system comprising a replacement module as a replacement for a defective high-voltage module, vehicle, stationary electrical energy storage device and method

Abstract

High-voltage storage system (3), in particular for a vehicle (1), with a plurality of high-voltage modules (4), each having at least one battery cell, with a bridging device (13), wherein the high-voltage storage system (3) has a replacement module (9) as the bridging device (13), wherein the replacement module (9) is arranged at a position assigned to a defective high-voltage module (4) instead of the defective high-voltage module (4) in the high-voltage storage system (3), and having a control device (6) which is designed to operate the high-voltage storage system (3) in a predetermined reduced-power mode when the replacement module (9) is arranged in the high-voltage storage system (3), wherein the bridging device (13) is designed to bridge an electrical connection assigned to the defective high-voltage module (4) within the plurality of high-voltage modules (4) in the event of a defect in one of the high-voltage modules (4), and in that the high-voltage storage system (3) provides a lower electrical voltage and / or a lower electrical power in the reduced-power mode compared to a normal mode of the high-voltage storage system (3),characterized in that , the control device (6) provides an adapted diagnostic function for diagnosing the high-voltage modules (4) in the reduced-power mode, wherein in the reduced-power mode the diagnostic function reduces a diagnostic threshold depending on the replacement module (9).

Description

The present invention relates to a high-voltage storage system having a plurality of high-voltage modules, each of which has at least one battery cell. In addition, the high-voltage storage system comprises a bridging device which is designed to bridge an electrical connection, which is assigned to the defective high-voltage module, within the plurality of high-voltage modules in the event of a defect in one of the high-voltage modules. The present invention further relates to a vehicle having such a high-voltage storage system. The invention also relates to a stationary electrical energy store having such a high-voltage storage system. Finally, the present invention relates to a method for operating a high-voltage storage system.Electric motors are used for propulsion in electric vehicles (BEV) and plug-in hybrid electric vehicles (PHEV). These electric motors are supplied with electrical energy from a high-voltage accumulator. Such a high-voltage accumulator usually comprises a plurality of high-voltage modules or high-voltage accumulator modules. These high-voltage modules are electrically connected to one another and are controlled by means of a control device or a storage management electronics. In this case, the control device tunes the safety and function of the high-voltage modules to the vehicle. If one of the high-voltage modules fails or is defective, the control unit enters a safe state and can block the high-voltage accumulator. In the case of a plug-in hybrid, it may be possible in certain cases to continue to operate with the engine in a restricted manner. A purely electrically driven vehicle, however, can no longer be operated and has to be towed or repaired. In general, the high-voltage accumulator can only function correctly if all high-voltage modules are functional.For the repair of a high-voltage module, it is necessary for this to be exchanged. In this case, it is often the case that these high-voltage modules are produced only in specific works and are supplied to a dealer when there is a need for repair. In this case, the delivery time of such a high-voltage module can take a long time, since battery modules or battery cells must not be transported with an aircraft on account of the chemical substances. Therefore, the transport of a high-voltage module over landing paths can take a significantly longer time.It is also known to use high-voltage accumulators or high-voltage modules in stationary electrical energy accumulators. For example, high-voltage modules made of electric vehicles or plug-in hybrids used for stationary electrical energy stores can be used. In this case, a single defective high-voltage module can cancel out the profitability of such a second-life application. In the case of stationary electrical energy stores of this type, the repair costs for a high-voltage module are often very high and the other, functional high-voltage modules are disposed of.For this purpose, DE 10 2010 053 942 A1 describes a disconnection and bridging circuit for a vehicle, in particular an electric vehicle, comprising a battery having at least one battery made of cells connected into a group, a sensor which can be output sensor data for detecting a fault of at least the cell, and at least one circuit breaker which can be activated as a function of the sensor data. In this case, a control device is designed and / or programmed to reversibly apply a circuit breaker signal to the circuit breaker for activating the circuit breaker.Furthermore, WO 2011 / 095630 A1 discloses a high-current battery system in which high operating current flows, in particular for vehicle drives. The high-current battery system comprises battery system monitoring electronics and a plurality of battery modules, which each include at least one rechargeable battery cell and which are electrically connected in series by means of an operating current line in such a way that an operating current flows through the operating current line during operation. At least one of the battery modules is configured as a bypass battery module which has a bypass switch and a bypass line which are configured and arranged such that, after the bypass switch has been switched from a normal operating position to a bypass position, the battery module is electrically bypassed by the bypass line, with the result that the operating current flows through the bypass line.Furthermore, DE 10 2013 114 892 A1 discloses a traction battery for a battery-electrically driven mobile work machine, in particular an industrial truck. The traction battery is designed as a high-power battery and has a battery tray, within which modules are arranged, which are each constructed from at least one battery cell. Furthermore, the modules are electrically connected in parallel with one another. Additionally, the modules may be deployed individually and the traction battery may be operated with a different number of modules. As a result, the capacity of the traction battery can be adapted to a requirement. In addition, module arrays can be provided which correspond in terms of their geometrical dimensions to a module and can be inserted into the battery tray instead of a module.DE 10 2008 015 350 A1 describes a fuel cell stack which is of modular construction. The fuel cell stack comprises a sub-assembly in the form of a holding device. This is a housing which is open on at least one side and is provided for receiving individual assemblies, for example individual fuel cells, fuel cell compartments including necessary cooling cells. In addition, a module or cell can be removed and the relevant cell can be replaced by a "cell dummy", which performs the electrical contacting in the same way as the exchanged module.KR 10 2015 0 032 077 A describes a battery module having a dummy cell and forms a prior art. It is the object of the present invention to show a solution how a time duration for starting up a high-voltage accumulator having a defective high-voltage module can be easily reduced. In addition, a corresponding vehicle and a stationary electrical energy store are to be provided.This object is achieved according to the invention by a high-voltage energy storage system, by a method, by a vehicle and by a stationary electrical energy store having the features according to the independent claims. Advantageous further developments of the present invention are specified in the dependent claims.A high-voltage storage system according to the invention comprises a plurality of high-voltage modules, each of which has at least one battery cell. In addition, the high-voltage storage system comprises a bridging device which is designed to bridge an electrical connection, which is assigned to the defective high-voltage module, within the plurality of high-voltage modules in the event of a defect in one of the high-voltage modules. In this case, the high-voltage accumulator system has a replacement module as the bridging device, the replacement module being arranged in the high-voltage accumulator system at a position assigned to the defective high-voltage module instead of the defective high-voltage module.The high-voltage storage system can preferably be used in a vehicle, for example an electric vehicle or a hybrid vehicle. The high-voltage storage system comprises the plurality of high-voltage modules. Each of the high-voltage modules comprises at least one battery cell. Each of the high-voltage modules preferably comprises a plurality of battery cells, wherein the battery cells within the battery module can be electrically connected to one another in series and / or in parallel. The respective battery cells are embodied in a rechargeable manner or in the form of so-called accumulators or secondary cells. The battery cells are electrochemical energy stores. The respective high-voltage modules can likewise be electrically connected to one another. For example, the high-voltage modules can be connected to one another in series and / or in parallel. An electrical voltage can thus be provided with the high-voltage storage system.According to one essential aspect of the present invention, it is provided that the high-voltage storage system has at least one replacement module. This replacement module serves as a bridging device. An electrical connection which is assigned to the defective high-voltage module can be bridged by this replacement module. This is realized in that the defective high-voltage module is replaced by the replacement module and the replacement module is arranged at the position of the defective high-voltage module instead of the defective high-voltage module in the high-voltage storage system. This replacement module can be electrically connected to at least one further high-voltage module and / or a connection of the high-voltage storage system to which the defective high-voltage module was also connected. An electrical connection between the at least one further high-voltage module and / or terminal has been provided with the defective high-voltage module. This electrical connection to corresponding contacts of the at least one further high-voltage module or of the connection is now bridged by means of the replacement module. In this case, it is provided in particular that no electrical energy is provided by means of the replacement module. This replacement module does not serve as a permanent replacement for the defective high-voltage module. In particular, it is provided that the replacement module does not have battery cells. Thus, a modular system can be provided, which has the high-voltage modules. If one of the high-voltage modules is defective, this can be replaced temporarily or permanently with the replacement module.In the event of a fault in a high-voltage module, the faulty high-voltage module can thus be replaced by the replacement module. This replacement module can also be referred to as a dummy module. In particular, this replacement module serves only to provide the electrical connection between the remaining high-voltage modules. Since the replacement module preferably does not comprise battery cells or chemical substances, it can be transported, for example, with an aircraft and thus quickly brought to the customer. This replacement module can be used as a temporary replacement part for the defective high-voltage module. Thus, operation of the vehicle, optionally restricted operation of the vehicle, in the case of a defective high-voltage module can be made possible. In this way, the time duration for the repair of the high-voltage accumulator system or of the high-voltage accumulator can be reduced.In addition, the high-voltage storage system has a control device which is designed to operate the high-voltage storage system in a predetermined power-reduced mode when the replacement module is arranged in the high-voltage storage system. The control device can also be referred to as memory management electronics. By means of this control device, the high-voltage storage system can be operated in a normal mode and in the power-reduced mode. The control device can have a corresponding processor on which a program is executed for carrying out the reduced-power mode and / or the normal mode. This program or corresponding program means can be stored on a memory of the control device. In this case, the high-voltage system can be transferred to reduced-power operation by a corresponding operator input or manual setting. It can also be provided that the replacement of the defective high-voltage module by the replacement module is automatically detected. For example, the high-voltage storage system may have corresponding sensors, by means of which the arrangement of the replacement module in the high-voltage storage system is detected. Overall, reliable operation of the high-voltage storage system can thus be ensured when using the replacement module.In this case, it is provided that the high-voltage accumulator system provides a lower electrical voltage and / or a lower electrical power in the power-reduced mode in comparison with a normal mode of the high-voltage accumulator system. It can be assumed, for example, that the high-voltage storage system has the predetermined number of high-voltage modules during normal operation. In this case, a predetermined electrical voltage is provided with each of the high-voltage modules. In this case, a rated voltage or a rated power, for example, can be provided. If one of the high-voltage modules is defective and this is replaced by the replacement module, however, no electrical voltage is provided with this replacement module. In this case, the high-voltage storage system can be operated in the reduced-power mode by means of the control device. In this case, the reduced electrical voltage and / or the reduced electrical power can be output in comparison with normal operation. For example, this reduced power or voltage can be reduced by the proportion which is otherwise provided with the exchanged high-voltage module. This reduced-power mode allows a vehicle to be operated further until the delivery of a replacement high-voltage module has taken place.Furthermore, in the reduced-power mode, the control device provides an adapted diagnostic function for diagnosing the high-voltage modules. During operation of the high-voltage storage system, the respective high-voltage modules or the battery cells can be monitored continuously. For this purpose, for example, an electrical voltage and / or an electrical current can be detected at the respective high-voltage modules or battery cells. A corresponding diagnostic threshold can be predefined for the diagnosis. In the reduced-power mode, this diagnostic threshold may be reduced accordingly. In this case, the diagnosis threshold is reduced in particular proportionally for the high-voltage module replaced by the replacement module. This also makes it possible to ensure diagnosis in the reduced-power mode.The replacement module preferably has a housing, wherein external dimensions of the housing correspond to external dimensions of the respective high-voltage modules. The respective high-voltage modules can have a plurality of battery cells which are connected to one another. The external dimensions of the individual high-voltage modules can be the same. The housing of the replacement module can have the shape and the external dimensions of these high-voltage modules. For example, the housing can be manufactured from an electrically insulating material, for example a plastic. It can also be provided that the high-voltage modules have a housing. In this case, the replacement module can have a housing which is designed identically to the housings of the high-voltage modules. The replacement module can be manufactured specifically for the high-voltage storage system or a vehicle type. The replacement module can thus be used with an exact fit instead of the defective high-voltage module.In a further embodiment, the replacement module has an electrical connection device for providing the electrical connection within the high-voltage modules. For example, this electrical connection device can be provided by a corresponding cable or the like. This electrical connecting device can be arranged at least in regions in the housing of the replacement module. In addition, the replacement module can have corresponding connection elements or poles, which correspond to the connection elements of the normal high-voltage modules. These connection elements can then be electrically connected to the connecting device. In other words, the replacement module does not provide an electrochemical energy store, but merely represents an electrical path. The electrical connection between the high-voltage modules can thus be provided by the electrical connection device. During operation of the high-voltage storage system, an electrical current flows through the electrical connecting device. Such a replacement module can be produced cost-effectively, since in the simplest case it consists only of the housing of the electrical connection device. Also, the production cost for manufacturing such a spare module is very low due to the simple structure. Furthermore, the advantage results that this replacement module can be used for different vehicles or high-voltage storage systems.As already explained, it is provided in particular that the replacement module is formed without battery cells. In the simplest case, the replacement module is an empty high-voltage module, in the housing of which no battery cells are arranged. Instead of the battery cells, the electrical connecting device or corresponding electrical lines can be used. The replacement module can thus be provided in a simple and cost-effective manner.A vehicle according to the invention comprises a high-voltage storage system according to the invention. In addition, the vehicle may have at least one electric motor or an electric machine which is supplied with electrical energy with the high-voltage storage system or the high-voltage modules. In addition, electrical energy can be supplied to the high-voltage modules during recuperation. Furthermore, the high-voltage modules can be charged by means of a corresponding charging station for the vehicle. The vehicle can be an electric vehicle or a purely electrically driven vehicle. The vehicle can also be a hybrid vehicle, in particular a so-called plug-in hybrid. The vehicle is designed in particular as a passenger car. It can also be provided that the vehicle is designed as a utility vehicle. The vehicle may also be an electrically driven motorcycle. In addition, the vehicle can be an electrically driven watercraft or an electrically driven aircraft. The high-voltage storage system can be used in principle in an electrically driven transport system.A stationary electrical energy store according to the invention comprises a high-voltage storage system according to the invention. In this so-called second-life application, used high-voltage modules from vehicles, for example, can be used. Here, too, a defective high-voltage module can be replaced by the replacement module. In this case, it can be provided that this replacement module is used permanently in the stationary energy store in order to be able to use the remaining functional high-voltage modules.A further aspect of the invention relates to a replacement module for a high-voltage storage system. In the case of a defective high-voltage module, this replacement module can be arranged at a position assigned to the defective high-voltage module in place of the defective high-voltage module in the high-voltage storage system. The replacement module can have a housing whose outer dimensions correspond to the outer dimensions of the defective high-voltage module. In addition, the replacement module can have an electrical connecting device which bridges an electrical connection assigned to the defective high-voltage module.A method according to the invention is used for operating a high-voltage accumulator system, wherein the high-voltage accumulator system comprises a plurality of high-voltage modules, each of which has at least one battery cell. In the event of a defect in one of the high-voltage modules, an electrical connection associated with the defective high-voltage module within the plurality of high-voltage modules is bridged by means of a bridging device. In this case, it is provided that the high-voltage accumulator system has a replacement module as the bridging device, the replacement module being arranged in the high-voltage accumulator system at a position assigned to the defective high-voltage module instead of the defective high-voltage module. Furthermore, when arranging the replacement module in the high-voltage storage system, the high-voltage storage system is operated in a predetermined power-reduced mode by means of a control device, wherein a lower electrical voltage and / or a lower electrical power is provided in the power-reduced mode in comparison with a normal mode of the high-voltage storage system.The preferred embodiments presented with reference to the high-voltage storage system according to the invention and the advantages thereof correspondingly apply to the vehicle according to the invention, to the stationary electrical energy store according to the invention, to the replacement module according to the invention and to the method according to the invention.Further features of the invention are evident from the claims, the figures and the description of the figures. The features and combinations of features mentioned above in the description and the features and combinations of features mentioned below in the description of the figures and / or shown alone in the figures can be used not only in the respectively specified combination but also in other combinations or alone.The invention will now be explained in more detail on the basis of a preferred exemplary embodiment and with reference to the drawings. The following are shown: FIG. 1 shows a schematic illustration of a vehicle which has a high-voltage storage system; and FIG. 2 shows a schematic illustration of the high-voltage accumulator system, which has a plurality of high-voltage modules and a replacement module.In the figures, identical or functionally identical elements are provided with the same reference numerals.FIG. 1 shows a schematic illustration of a vehicle 1 in a plan view. The vehicle 1 comprises an electric machine 2, by means of which the vehicle 1 can be driven. Furthermore, the vehicle 1 comprises a high-voltage storage system 3, which serves to supply the electric machine 2 with electrical energy. In addition, electrical energy can be transmitted from the electric machine 2 to the high-voltage storage system 3. The vehicle 1 can be designed as an electric vehicle or as a plug-in hybrid.FIG. 2 shows a greatly simplified illustration of the high-voltage storage system 3 of the vehicle 1. The respective high-voltage modules 4 have an outer contour 5 with specific external dimensions. The high-voltage modules 4 can have at least one battery cell. The respective high-voltage modules 4 preferably have a plurality of battery cells which are electrically connected to one another. Furthermore, the high-voltage storage system 3 comprises a control device 6, by means of which the operation of the high-voltage modules 4 can be controlled.In normal operation of the high-voltage accumulator system 3, it is provided that it has, for example, six high-voltage modules 4, which are electrically connected in series. The respective high-voltage modules 4 have connection elements 7, to which they can be electrically contacted. In normal operation, the connection elements 7 of two adjacent high-voltage modules 4 can be electrically connected by means of a line element 8. During normal operation of the high-voltage storage system 3, an electrical power of 20 kWh or a voltage between 300 V and 400 V can be provided with the high-voltage modules 4 connected in series.In the present example, the high-voltage storage system 3 has a replacement module 9, which replaces a defective high-voltage module. This replacement module 9 does not have battery cells, but rather serves merely to bridge an electrical connection which is otherwise provided with the defective high-voltage module. The replacement module 9 thus serves as a bridging device 13. This replacement module 9 has a housing 10 whose shape corresponds to the outer contour 5 of the high-voltage modules 4. The outer dimensions of the housing 10 therefore correspond to the outer dimensions of the high-voltage modules 4. In addition, the replacement module 9 comprises corresponding connection elements 11, which are likewise of identical construction to the connection elements 7 of the high-voltage modules 4. Furthermore, the replacement module 9 comprises an electrical connecting device 12 by means of which an electrical connection can be provided between the high-voltage modules 4, which adjoin the replacement module 9 or which are otherwise electrically connected to the defective high-voltage module. This connection device 12 can be provided by a corresponding cable or a line and this connection device 12 can be arranged in the housing 10.If the replacement module 9 is arranged in the high-voltage storage system 3, the high-voltage storage system 3 can be operated in a reduced-power mode by means of the control device 6. In this case, a reduced electrical power and / or reduced electrical voltage can be provided in comparison with normal operation. For example, an electrical power of 16.5 kWh and / or an electrical voltage between 250 V and 340 V can be provided.The replacement module 9, which can also be referred to as a dummy module, has the advantage that it can be provided with very low production costs by the simple structure. In addition, the replacement module 9 can be transported in an aircraft since it does not contain any chemical substances, but rather consists only of the housing 10 and the electrical connection device 11. Such a replacement module 9 can be used very often as a temporary replacement part for high-voltage storage devices or vehicles 1 and can be used on different customers.In the same way, such a high-voltage storage system 3 can be used in a stationary electrical energy store. If such a stationary electrical energy store has a defective high-voltage module 4, it can be permanently replaced by a replacement module 9, for example. The residual potential of the remaining high-voltage modules 4 can thus be exhausted.

Claims

High-voltage storage system (3), in particular for a vehicle (1), having a plurality of high-voltage modules (4) which each have at least one battery cell, having a bridging device (13), the high-voltage storage system (3) having a replacement module (9) as the bridging device (13), the replacement module (9) being arranged in the high-voltage storage system (3) at a position assigned to a defective high-voltage module (4) instead of the defective high-voltage module (4), and having a control device (6) which is designed to operate the high-voltage storage system (3) in a predetermined power-reduced mode when the replacement module (9) is arranged in the high-voltage storage system (3), the bridging device (13) being designed to operate the high-voltage storage system (3) in a predetermined power-reduced mode, in the event of the fault of one of the high-voltage modules (4) to bridge an electrical connection within the plurality of high-voltage modules (4) assigned to the faulty high-voltage module (4) and in that the high-voltage storage system (3) provides a lower electrical voltage and / or a lower electrical power in the reduced-power mode compared to a normal mode of the high-voltage storage system (3), characterized in that the control device (6) provides an adapted diagnostic function for the diagnosis of the high-voltage modules (4) in the reduced-power mode, wherein the diagnostic function reduces a diagnostic threshold in dependence on the replacement module (9).High-voltage storage system (3) according to Claim 1, characterized in that the replacement module (9) has a housing (10), external dimensions of the housing (10) corresponding to external dimensions of the respective high-voltage modules (4).High-voltage storage system (3) according to Claim 1 or 2, characterized in that the replacement module (9) has an electrical connection device (12) for providing the electrical connection within the high-voltage modules (4).High-voltage storage system (3) according to one of the preceding claims, characterized in that the replacement module (9) is designed without battery cells.Vehicle (1) having a high-voltage storage system (3) according to one of the preceding claims.Stationary electrical energy store having a high-voltage storage system (3) according to one of Claims 1 to 4.Method for operating high-voltage accumulator system (3), in particular for a vehicle (1), wherein the high-voltage accumulator system (3) comprises a plurality of high-voltage modules (4) which each have at least one battery cell, and wherein the high-voltage accumulator system (3) has a replacement module (9) as a bridging device (13), wherein the replacement module (9) is arranged in the high-voltage accumulator system (3) instead of the defective high-voltage module (4) at a position assigned to a defective high-voltage module (4), and wherein the high-voltage accumulator system (3) is operated in a predetermined power-reduced mode by means of a control device (6) when the replacement module (9) is arranged in the high-voltage accumulator system (3), characterized in that, in the event of a defect in one of the high-voltage modules (4), an electrical connection associated with the defective high-voltage module (4) within the plurality of high-voltage modules (4) is bridged by means of a bridging device (13), and a lower electrical voltage and / or a lower electrical power is provided in the power-reduced mode in comparison with a normal mode of the high-voltage storage system (3).

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