Replacement module for replacing a defective insert module of a battery device

Abstract

Replacement module (10) for replacing a defective insert module (110) of a battery device (100) with a plurality of insert modules (110), wherein the replacement module (10) is free of battery cells or storage cells compared to the insert modules, comprising a module frame (20) with at least one fastening section (22) for fastening in a battery frame (120) of the battery device (100) and with at least two connection sections (24) for an electrically conductive connection to corresponding mating connection sections (124) of adjacent insert modules (110), wherein the at least two connection sections (24) are electrically connected to each other via a connecting device (30), and a voltage module (50) arranged in and / or on the module frame (20) for adjusting the operating voltage of the replacement module (10) and / or the battery device (100).

Description

[0001] The present invention relates to a replacement module for replacing a defective insert module of a battery device, a battery device with such a replacement module, a method for operating such a battery device and a method for replacing a defective insert module in a battery device.

[0002] It is known that battery devices are used to provide electrical energy, particularly for electric vehicles. These include vehicle battery devices that form an electrical storage device within the vehicle. However, battery devices are also known that are used as buffer storage devices in charging stations, so to speak, to absorb electrical power from a correspondingly connected power grid and temporarily store it until an electric vehicle needs to be charged again. At this time, the electrical power is then withdrawn from the battery device. Such battery devices in charging stations can also be referred to as stationary battery devices.

[0003] A disadvantage of the known solutions is that a battery device is vulnerable in terms of usability. This is due in particular to aging mechanisms and other defects that can lead to individual battery cells or individual battery modules no longer being sufficiently functional. Typically, a battery device consists of one or more battery frames, with a plurality of insert modules arranged in each of these battery frames. Each of these insert modules is usually configured with the same or a similar number of battery cells, which represent the smallest storage unit for electrical power in the battery device. The individual insert modules are usually electrically connected in series in the battery frame so that together they provide the desired electrical power capacity in the form of a high voltage.However, this means that if a single cell and / or a single insert module fails, the entire series connection, including the neighboring, still functional insert modules, is no longer available for electrical power output or input. With known solutions, this results in the defective insert modules being exchanged and replaced with functional insert modules. However, this has several critical disadvantages. Firstly, storing such insert modules involves similar risks to operating the battery device at the respective location. For example, insert modules stored near a battery device as a spare may also be subject to the same aging process and no longer have the desired full performance at the time of replacement or may even already be defective.Storage that maintains performance requires storage within a specific temperature range and monitoring the cell voltage(s) with appropriate recharging. This makes such storage complex and expensive. The transport of such modules is also complex. In particular, depending on the legislation at the location of the battery device, the transport of modules may only be carried out as hazardous goods. Last but not least, the handling and assembly of such modules is also associated with considerable effort.

[0004] DE 10 2009 000 674 A1 discloses a traction battery with increased availability. The traction battery comprises at least two battery modules. Each battery module has module terminals and a plurality of battery cells connected between the module terminals. At least one battery module has two disconnect devices and a bridging device. The bridging device can short-circuit the module terminals.

[0005] KR 10 2015 0 032 077 A discloses a replacement module for replacing a defective insert module of a battery device having a plurality of insert modules, comprising a module frame with at least one fastening section for fastening in a battery frame of the battery device and with at least two connection sections for an electrically conductive connection to corresponding mating connection sections of adjacent insert modules, wherein the at least two connection sections are electrically conductively connected to one another via a connecting device.

[0006] EP 1 650 879 A2 discloses a battery modem with near-field radio technology.

[0007] The object of the present invention is to at least partially remedy the disadvantages described above. In particular, the object of the present invention is to be able to restore the operational capability of a battery device with a defective insert module as quickly as possible in a cost-effective and simple manner.

[0008] The above object is achieved by a replacement module having the features of claim 1, a battery device having the features of claim 7, a method having the features of claim 8, and a method having the features of claim 10. Further features and details of the invention emerge from the subclaims, the description, and the drawings. Features and details described in connection with the replacement module according to the invention naturally also apply in connection with the battery device according to the invention, the operating method according to the invention, and the replacement method according to the invention, and vice versa, so that reciprocal reference is or can always be made to the individual aspects of the invention with regard to the disclosure.

[0009] According to the invention, a replacement module serves to replace a defective insert module of a battery device having a plurality of insert modules. For this purpose, the replacement module has a module frame with at least one fastening section for fastening in a battery frame of the battery device. The module frame is further designed with at least two connection sections for an electrically conductive connection to corresponding mating connection sections of adjacent insert modules. The at least two connection sections are electrically conductively connected to one another via a connecting device. The replacement module further has a voltage module arranged in and / or on the module frame for adjusting the operating voltage of the replacement module and / or the battery device.

[0010] A replacement module according to the invention is based on known insert modules, but lacks inserted battery cells. In other words, the replacement module is designed without battery cells or storage cells compared to the insert modules. Such a replacement module is, so to speak, a virtual insert module, but without any storage capacity for electrical power.

[0011] The replacement module serves exclusively to fill the gap created when a defective insert module is replaced. The individual insert modules usually all have identical or essentially identical geometric dimensions. If one of the insert modules is removed, this results in the series connection being canceled because an insert module is missing, which would otherwise have completed the series connection. This is where a replacement module according to the invention comes in, as it has, in particular, identical or essentially identical external connection geometries to the insert modules. It therefore replaces the defective insert module at the location of the defective insert module, at least geometrically and, above all, in an electrically conductive manner.The replacement module essentially serves exclusively to restore the electrically conductive connection between the still intact insert modules of the battery device and to complete the electrical series connection again.

[0012] However, this completion of the electrical series circuit is based on a very simple design principle, as the replacement module is designed without its own electrical storage capacity. In the simplest case, it is a module frame with an electrical conductor arranged within it and the corresponding connection sections. This means that such a replacement module can be manufactured very easily and cost-effectively. Storage is also simple and permanently stable, as no aging processes need to be considered, as is the case with storage cells in a battery device. Last but not least, transporting such a replacement module is also simple and cost-effective, as the usual restrictions on storage cells and the corresponding hazardous goods transport conditions do not need to be taken into account here.

[0013] Compared to existing solutions, this makes it possible to store replacement modules, which are significantly more cost-effective than insert modules, directly at the battery device's operating location, without having to consider the aging processes of the replacement module. Additionally or alternatively, such replacement modules can also be stored and transported in a maintenance vehicle, so that they are immediately available and ready for installation upon the arrival of a maintenance technician.

[0014] According to the invention, a replacement module is provided which, from an electrical perspective, simulates an insert module and is thus capable of restoring electrical conductivity in the battery device. Although this battery device will then lack part of the battery storage capacity, for example, approximately 3-5 kWh, the remaining intact insert modules can still be used in this way. The entire battery device therefore no longer needs to wait for replacement with an intact insert module, and it also does not need to be switched off, since the replacement module provides functionality with reduced storage capacity.

[0015] In the replacement module according to the invention, a voltage module is arranged in and / or on the module frame for adjusting the operating voltage of the replacement module and / or the battery device.

[0016] Because the replacement module is empty and lacks storage capacity, its installation in the series circuit between other insert modules slightly changes the operating voltage. Such a voltage module allows for the voltage drop caused by the missing insert module to be compensated for or communicated via feedback to a control device in the battery device. This is particularly useful if two or more replacement modules are installed in the battery device, so that the corresponding voltage drop is added together for each inserted replacement module.

[0017] It can be advantageous if, in a replacement module according to the invention, the connecting device comprises a connecting cable, in particular comprising an electrically conductive metal. Such a connecting cable or also a connecting rail can have its own insulation. Tab-like or flat-band-like connecting devices are also conceivable within the meaning of the present invention. Copper is used in particular as the electrically conductive material. The connecting device can be conductively connected to the corresponding connection sections. This connection can be provided by a flat or point-like contact. The connection between the connecting device and the connection sections can in particular be irreversible, for example by soldering or welding, or reversibly in the form of a screw connection.

[0018] It is also advantageous if a replacement module according to the invention is provided with a module control device, which is arranged in particular in and / or on the module frame. Such a module control device can, for example, be designed as a battery management system or have such a system. The module control device is preferably connected to the connecting device in an electrically conductive manner or in a signal-communicating manner, as will be explained later. The module control device allows communication with other module control devices of the insert modules. Alternatively or additionally, the module control device can be connected to a corresponding central control device, i.e. a battery controller of the battery device, in a signal-communicating manner. This allows, in addition to the purely electrical restoration of the functionality of the battery device, control-related orTo achieve control-related restoration of the functionality of the battery device. In other words, the module control device helps to simulate a virtual deployment module for the entire battery device system through the replacement module, also in terms of control technology.

[0019] It is also advantageous if, in a replacement module according to the preceding paragraph, the module control device is connected to the battery control device in an electrically conductive and / or signal-communicating manner. This can be, for example, a conductive connection or a measuring connection. A sensor connection is also conceivable to ensure detection of the flowing currents or, in general, the functionality of the connecting device. Last but not least, the module control device can also be supplied with the necessary operating current via an electrically conductive connection to the connecting device.

[0020] The voltage module can be part of the module control device.

[0021] It is also advantageous if, in a replacement module according to the invention, a state module is arranged in and / or on the module frame for outputting a state of charge variable, in particular depending on a state of charge variable of neighboring insert modules of the battery devices. Such a state of charge can be referred to, for example, as a state of charge (SOC). Typically, the parameters of the state of charge variables are used to maintain the individual modules or the individual cells of the battery device at similar states of charge. This results in active discharging of overcharged modules in order to avoid undesirable inequalities in the states of charge. This process is also called balancing.Because the state module now uses the information of real state of charge variables to forward a virtual state of charge variable to other module control devices, undesirable balancing can be avoided.

[0022] The present invention also relates to a battery device comprising a plurality of insert modules electrically connected in series for storing electrical energy. At least one of the insert modules is replaced by a replacement module according to the invention. A battery device according to the invention thus offers the same advantages as have been explained in detail with reference to a replacement module according to the invention. Such a battery device can be used both in a vehicle and as an intermediate storage device at charging positions or charging stations. Each insert module can have, for example, 8 to 20 individual battery cells for storing energy. For example, 10 to 20 insert modules can be provided per battery device or per battery frame.It is possible that a single or multiple replacement modules for one or more defective insert modules are already installed in the battery device.

[0023] The present invention also relates to a method for operating a battery device according to the present invention, comprising the following steps: - generating at least one virtual operating parameter for the at least one replacement module based on a corresponding real operating parameter of an insert module, - Using the generated virtual operating parameter for the operation of the battery device.

[0024] A method according to the invention thus provides the same advantages as those explained in detail with reference to a battery device according to the invention and with reference to a replacement module according to the invention. It allows a replacement module to be virtually represented as an insert module and to be simulated as an insert module for the overall system of the battery device in terms of signal communication, measurement technology, and / or electrical functions. This simulation can be achieved, for example, by generating one or more virtual operating parameters, such as those already explained with reference to the voltage situation or the state of charge.

[0025] It is further advantageous if, in a method according to the invention, at least one of the following real operating parameters is taken into account when determining the virtual operating parameter: - Charge level of at least one insert module - Stress state of at least one insert module

[0026] The above list is not exhaustive.

[0027] The individual operating parameters can be measured or specified in a defined manner. In addition to measurements, the defined specification can make such measurements obsolete, allowing the method according to the invention to be used even more simply and, in particular, without feedback from other measurement systems.

[0028] The present invention also relates to a method for replacing a defective insert module in a battery device having a plurality of insert modules, comprising the following steps: - Determine a defective insert module - Removal of the defective insert module from the battery device, - Mounting a replacement module according to the present invention instead of the removed defective insert module, - Creating an electrically conductive connection between the connection sections of the replacement module and the mating connection sections of the adjacent insert modules.

[0029] A replacement method according to the invention results in a battery device according to the invention, so that the same advantages are achieved as explained in detail with reference to a replacement module according to the invention and with reference to a battery device according to the invention. The individual insert modules may, for example, exhibit a defect or a reduction in performance due to aging, electrical failure, or the like. Of course, an arrangement at the edge of the insert modules is also conceivable, so that the corresponding connection sections are connected to an adjacent insert module and a corresponding connection option of the battery device.

[0030] Further advantages, features, and details of the invention will become apparent from the following description, which describes embodiments of the invention in detail with reference to the drawings. The features mentioned in the claims and in the description may be essential to the invention individually or in any combination. They show schematically: Fig. 1 an embodiment of a battery device with intact insert module, Fig. 2 a situation during the replacement of a defective insert module, Fig. 3 an embodiment of a battery device according to the invention, Fig. 4 shows a further embodiment of a battery device according to the invention, Fig. 5 is a schematic exploded view of a battery device and Fig. 6 shows a further embodiment of a replacement module according to the invention.

[0031] Based on the Fig. 1 to 3, a replacement process is explained below, in which a version of a replacement module 10 according to the invention is inserted into a battery device 100. In the normal state, a battery device 100 according to the Fig. 1 is equipped with a plurality of insert modules 110. Each insert module 110 contains a defined number of battery cells 112. In this state, the electrical and signal communication control of all series-connected insert modules 110 is carried out via a battery control device 130. Each insert module 110 can also have its own cell control device, which is then connected to the battery control device 130.

[0032] For example, if the second insert module 110 is defective when viewed from the left, it can be removed as shown in the Fig. 2. Here it is also clearly visible that the corresponding mating connection sections 124 of the left insert module 110 remain free within the battery frame 120, so that the electrical series connection has an interruption. Fig. In the situation shown in Figure 2, the battery device 100 is de-energized, so that neither electrical energy can be stored nor discharged. According to the invention, Fig. 3 into the resulting gap of the Fig. 2, a replacement module 10 is installed. This allows the module frame 20 to fill this gap and, in particular, to electrically contact the corresponding adjacent mating connection sections 124 with their own connection sections 24 of the module frame 20. In this position, a fixed mounting in the battery frame 120 can also be provided via the module frame 20 via the fastening section 22.

[0033] Again Fig. 3, at least one electrical connecting cable 32 or an electrical connecting rail 32 of a connecting device 30 is provided in the interior of this replacement module 10, which completes the series connection of the remaining insert modules 110 of the battery device 100. In this representation of the Fig. 3, i.e. after the replacement module 10 has been inserted, the battery device 100 is again in an electrically intact situation, so that electrical energy can be stored and discharged.

[0034] The Fig. 4 shows a further development of the embodiment of the Fig. 3, wherein a different supplementary replacement module 10 has been inserted. The basic functionality when replacing or using the replacement module 10 remains identical. However, a module control device 40 is additionally arranged on the replacement module 10. This has a voltage module 50 and a status module 60, so that a simulation of a virtual deployment module 110 can also be carried out by the replacement module 10 in a signal-communicating and electrical manner. For this purpose, the module control device 40 is preferably in signal-communicating contact with the battery control device 130.

[0035] Fig. Figure 5 schematically shows how the individual insert modules 110 can be arranged in a battery frame 120 of a battery device 100. Here, a plurality of insert modules 110, each with a defined number of battery cells 112, is shown in an exploded view in a drawer-like manner. These can then be inserted into corresponding receptacles in the battery frame 120 to achieve the functional position with electrically conductive contact.

[0036] Fig. Figure 6 shows a replacement module 10 for use in the embodiment according to Fig. 5. The empty module frame 20 of the replacement module 10 is clearly visible there. This provides a large cavity in which the battery cells 112 would otherwise be located. The corresponding connection sections 24 and the corresponding fastening section 22 can be seen on the side.

[0037] The above explanation of the embodiments describes the present invention exclusively by way of examples. Of course, individual features of the embodiments can be freely combined with one another, provided they are technically feasible, without departing from the scope of the present invention.

Claims

[1] Replacement module (10) for replacing a defective insert module (110) of a battery device (100) having a plurality of insert modules (110), wherein the replacement module (10) is free of battery cells or storage cells compared to the insert modules, comprising a module frame (20) with at least one fastening section (22) for fastening in a battery frame (120) of the battery device (100) and with at least two connection sections (24) for an electrically conductive connection to corresponding mating connection sections (124) of adjacent insert modules (110), wherein the at least two connection sections (24) are electrically conductively connected to one another via a connecting device (30), and a voltage module (50) arranged in and / or on the module frame (20) for adjusting the operating voltage of the replacement module (10) and / or the battery device (100). [2] Replacement module (10) according to claim 1, characterized bythat the connecting device (30) comprises a connecting cable or a connecting rail (32), in particular comprising an electrically conductive metal. [3] Replacement module (10) according to one of the preceding claims, characterized by that a module control device (40) is provided and is arranged in particular in and / or on the module frame (20). [4] Replacement module (10) according to claim 3, characterized by that the module control device (40) is connected to the battery control device (130) in an electrically conductive and / or signal-communicating manner. [5] Replacement module (10) according to claim 3 or 4, characterized by that the voltage module (50) is part of the module control device (40). [6] Replacement module (10) according to one of the preceding claims, characterized bythat a state module (60) is arranged in and / or on the module frame (20) for outputting a state of charge variable, in particular as a function of a state of charge variable of adjacent insert modules (110) of the battery device (100). [7] Battery device (100) comprising a plurality of insert modules (110) electrically connected in series with one another for storing electrical energy, wherein at least one of the insert modules (110) is replaced by a replacement module (10) having the features of one of claims 1 to 6. [8] A method for operating a battery device (100) having the features of claim 7, comprising the following steps: - generating at least one virtual operating parameter for the at least one replacement module (10) on the basis of a corresponding real operating parameter of an insert module (110), - Using the generated virtual operating parameter for the operation of the battery device (100). [9] Method according to claim 8, characterized by that at least one of the following real operating parameters is taken into account when determining the virtual operating parameter: - charge state of at least one insert module (110), - stress state of at least one insert module (110). [10] Method for replacing a defective insert module (110) in a battery device (100) having a plurality of insert modules (110), comprising the following steps: - Determining a defective insert module (110), - removal of the defective insert module (110) from the battery device (100), - mounting a replacement module (10) having the features of one of claims 1 to 6 instead of the removed, defective insert module (110), - Creating an electrically conductive connection between the connection sections (24) of the replacement module (10) and the counter-connection sections (124) of the adjacent insert modules (110).

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