Method, control device, battery housing diagnostic device and computer program for detecting damage to a vehicle battery housing, as well as battery device and vehicle

Abstract

The present invention relates to a method, a control device (160), a battery housing diagnostic device (170), and a computer program for detecting damage to a vehicle battery housing (110), as well as a battery arrangement (100) and a vehicle. An ultrasonic device (140) is provided, which is configured to couple at least one ultrasonic transmission signal into the wall of the battery housing (110) and to receive the at least one ultrasonic transmission signal propagated through the wall of the battery housing (110) as an ultrasonic response signal.The method according to the invention comprises sending a diagnostic signal that causes the ultrasound device (140) to couple at least one predetermined ultrasound transmission signal into the wall of the battery housing (110), receiving an ultrasound response signal from the ultrasound device (110), detecting damage to the battery housing (110) if the received ultrasound response signal deviates from a predetermined ultrasound response signal by more than a threshold value, and sending a damage signal when damage to the battery housing (110) has been detected, wherein the damage signal indicates that damage to the battery housing (110) is present.

Description

[0001] The present invention relates to a method, a control device, a battery housing diagnostic device, a vehicle, a computer program and a computer-readable medium with the computer program for determining damage to a vehicle battery housing, as well as a vehicle battery housing and a vehicle.

[0002] Lithium-ion batteries are currently used in electromobility, both in hybrid and fully electric vehicles. Lithium-ion batteries use aluminum electrodes on the cathode side and copper electrodes on the anode side as current collectors, usually in foil form. Lithium transition metal oxides, such as cobalt, manganese, and nickel, are used as the cathode material, and carbon / graphite is used as the anode material. The electrolyte in between consists of an organic solvent with dissolved electrolyte salts. To prevent short circuits, a separator permeable to lithium ions (e.g., made of polypropylene) can be placed between the electrodes.

[0003] Such battery assemblies are typically housed in battery enclosures that protect the battery assembly from environmental influences. Accordingly, it is important that the battery enclosures are not damaged, as otherwise they can no longer fulfill their protective function. Damage, such as a dent or even a hole, could significantly increase the likelihood of damage to the battery assembly located within the battery enclosure.

[0004] The present invention is essentially based on the object of determining damage to a battery housing for a battery arrangement of a vehicle in a simple and reliable manner.

[0005] This object is achieved with a method according to independent claim 1, a control device according to claim 6, a battery housing diagnostic device according to claim 9, a battery device according to claim 11, a vehicle according to claim 12, a computer program according to claim 13, and a computer-readable medium according to claim 14. Advantageous embodiments are specified in the subclaims.

[0006] The present invention is essentially based on the idea of ​​checking a battery housing of a battery device for a vehicle for damage by coupling predetermined ultrasonic signals into the wall of the battery housing using an ultrasonic device, which has, for example, an ultrasonic transmitter arranged on the battery housing and an ultrasonic transducer arranged on the battery housing. The ultrasonic signals received as ultrasonic response signals after propagating through the wall of the battery housing are evaluated to determine whether the battery housing is damaged. In particular, it has been shown that an undamaged battery housing has a predetermined (expected) ultrasonic response signal, whereas the ultrasonic response signal from a damaged battery housing is different.Accordingly, by evaluating the ultrasonic response signal, it can be determined whether there is any damage to the battery housing, such as a dent, a bulge, a crack, or the like. A further advantage is that this check can be performed independently of a damage event, particularly after a damage event while the vehicle is in a static state.

[0007] Consequently, according to a first aspect of the present invention, a method for determining damage to a battery housing of a battery device for a vehicle, said battery housing accommodating a battery assembly, is disclosed. An ultrasonic device is provided that is configured to couple at least one ultrasonic transmission signal into the wall of the battery housing and to receive the at least one ultrasonic transmission signal propagated through the wall of the battery housing as an ultrasonic response signal. The method according to the invention comprises transmitting a diagnostic signal that causes the ultrasonic device to couple at least one predetermined ultrasonic transmission signal into the wall of the battery housing, and receiving an ultrasonic response signal from the ultrasonic device.The ultrasonic response signal is representative of the ultrasonic transmission signal received by the ultrasonic device in response to the coupling of the predetermined ultrasonic transmission signal into the wall of the battery housing and propagated through the wall of the battery housing. The method according to the invention further comprises determining damage to the battery housing if the received ultrasonic response signal deviates from a predetermined ultrasonic response signal by more than a threshold value, and transmitting a damage signal if damage to the battery housing has been detected. The damage signal is representative of damage to the battery housing.

[0008] Preferably, the predetermined ultrasonic transmission signal has at least one predetermined frequency.

[0009] In a further preferred embodiment of the method according to the invention, determining damage to the battery housing comprises determining an attenuation between the predetermined ultrasonic transmission signal and the received ultrasonic response signal and determining damage to the battery housing if the determined attenuation deviates from a predetermined attenuation value by more than an attenuation threshold value.

[0010] It has been found that an undamaged battery casing attenuates the predetermined ultrasonic transmission signal as expected, whereas the attenuation of the ultrasonic transmission signal propagated through the wall of a damaged battery casing differs. By determining and evaluating the attenuation of the predetermined ultrasonic transmission signal caused by the wall of the battery casing, damage to the battery casing can be detected or determined.

[0011] In a further preferred embodiment of the method according to the invention, the harmonic spectrum of the ultrasonic response signal is evaluated when detecting damage to the battery casing. For example, the change in the harmonic spectrum can be evaluated.

[0012] In a further preferred embodiment of the method according to the invention, an acceleration sensor is further arranged on the battery housing, which is designed to generate an acceleration signal representative of an acceleration of the battery housing. In such a preferred embodiment, the method according to the invention further comprises receiving an acceleration signal from the acceleration sensor and determining that the received acceleration signal indicates an acceleration value that exceeds a predetermined acceleration threshold. Determining damage to the battery housing is based at least partially on determining that the received acceleration signal indicates an acceleration value that exceeds the predetermined acceleration threshold.

[0013] By additionally evaluating the received acceleration signal, it is possible to detect, in particular, an abnormal acceleration of the battery housing, which occurs, for example, in the event of damage, such as an impact on the battery housing, which may necessitate a subsequent examination of the battery housing according to the invention using the ultrasound device.

[0014] According to a further aspect of the present invention, a control device is disclosed which is designed to carry out the steps of a method according to the invention for determining damage to a battery housing of a battery device for a vehicle which accommodates a battery arrangement.

[0015] Preferably, the control device according to the invention comprises a first control device section for carrying out the step of transmitting the diagnostic signal to the ultrasonic device, a second control device section for carrying out the step of receiving the ultrasonic response signal from the ultrasonic device, a third control device section for carrying out the step of determining damage to the battery case, and a fourth control device section for carrying out the step of transmitting the damage signal.

[0016] In yet another preferred embodiment, the control device according to the invention further comprises a fifth control device section for carrying out the step of receiving an acceleration signal from the acceleration sensor and a sixth control device section for carrying out the step of determining that the received acceleration signal indicates an acceleration value that exceeds a predetermined acceleration threshold value.

[0017] According to yet another aspect of the present invention, a battery housing diagnostic device is disclosed, comprising an ultrasonic device configured to be attached to a battery housing of a battery device for a vehicle, and a control device according to the invention. The ultrasonic device is configured to couple at least one ultrasonic transmission signal into the wall of the battery housing and to receive the at least one ultrasonic transmission signal propagated through the wall of the battery housing as an ultrasonic response signal.

[0018] In a preferred embodiment, the battery housing diagnostic device according to the invention further comprises an acceleration sensor which is designed to be attached to the battery housing and to generate an acceleration signal which is representative of the acceleration of the battery housing.

[0019] According to yet another aspect of the present invention, a battery device for a vehicle is disclosed, comprising a battery housing, a battery assembly disposed in the battery housing, and a battery housing diagnostic device according to the invention.

[0020] According to yet another aspect of the present invention, a vehicle having a battery device according to the invention is disclosed.

[0021] According to yet another aspect of the present invention, a computer program is disclosed comprising instructions which, when executed by a computing unit, cause the computing unit to execute a method according to the invention for determining damage to a battery housing of a battery device for a vehicle.

[0022] According to yet another aspect of the present invention, a computer-readable medium is disclosed on which the computer program according to the invention is stored.

[0023] Further advantages and features of the present invention will become apparent to those skilled in the art by practicing the teachings described herein and viewing the accompanying single drawings in which: Fig. 1 shows a schematic representation of a battery housing according to the invention for a vehicle, and Fig. 2 an exemplary flow diagram of a method according to the invention for determining damage to the battery housing of the Fig. 1 shows.

[0024] In the context of the present disclosure, the term "damage" describes mechanical damage and / or at least partial plastic deformation of the affected component, in particular the battery housing. This can include, for example, a dent, a bulge, a crack, a hole, a defective weld, or other abnormalities in the wall of the battery housing.

[0025] The Fig. 1 shows a battery device 100 according to the invention, which has a battery housing 110 designed to accommodate a battery assembly 120. The battery assembly 120 can, as is known from the prior art, have at least one battery cell. Fig. 1, the battery arrangement 120 is shown schematically as a block, it being obvious to a person skilled in the art that the battery arrangement 120 and the battery cells can be arranged and interconnected as known in the art.

[0026] At this point, it should be noted that the "interior of the battery housing 110" comprises the free area surrounding the battery assembly 120. In particular, this is the fluid-filled, preferably air-filled, area around the battery assembly 120 located within the battery housing 110.

[0027] The battery device 100 further comprises a battery case diagnostic device 170, which is arranged in the Fig. 1 comprises an ultrasonic device 140, an acceleration sensor 150 and a control device 160.

[0028] The ultrasound device 140 has in the Fig. 1, the battery housing 110 comprises an ultrasonic transmitter 142 and an ultrasonic receiver 144, both of which are mounted on the wall, in particular the outer wall, of the battery housing 110. In an alternative embodiment, the ultrasonic transmitter 142 and / or ultrasonic receiver 144 can also be mounted on an inner side of the wall of the battery housing 110, i.e., inside the battery housing 110. Additionally or alternatively, the ultrasonic transmitter 142 and the ultrasonic receiver 144 can be an ultrasonic transducer configured to both transmit and receive ultrasonic signals into the wall of the battery housing.

[0029] The ultrasonic device 140, in particular the ultrasonic transmitter 142, is designed to couple a predetermined ultrasonic signal into the wall of the battery housing 110. For example, the ultrasonic transmitter 142 can comprise a piezo element designed to excite the wall of the battery housing 110 with ultrasonic waves. The predetermined ultrasonic signal can preferably have a predetermined frequency.

[0030] The ultrasonic device 140, in particular the ultrasonic receiver 144, is further configured to receive the ultrasonic signals coupled into the wall of the battery housing 110 by the ultrasonic transmitter 142 after propagating through the wall of the battery housing 110 as an ultrasonic response signal and to forward them to the control device 160. For example, the ultrasonic receiver 144 can have a piezo element configured to receive the ultrasonic waves coupled into the wall of the battery housing 110 by the ultrasonic transmitter 142 and to transform them back into an electrical signal.

[0031] It is expressly mentioned at this point that the arrangement of the ultrasonic transmitter 142 and ultrasonic receiver 144 can be chosen arbitrarily and is therefore not limited to the arrangement shown in the Fig. 1. For example, it may be preferable for the ultrasonic transmitter 142 and the ultrasonic receiver 144 to be arranged on opposite sides of the battery housing 110. Furthermore, it may be preferable for the ultrasonic device to have a plurality of ultrasonic transmitters 142 and a plurality of ultrasonic receivers 144. This can ensure redundancy in the detection of damage to the battery housing 110, whereby damage to the battery housing can be detected in an even more reliable manner. Furthermore, the provision of a plurality of ultrasonic transmitters 142 and / or ultrasonic receivers 144 can increase the scanning range of the wall of the battery housing and / or can enable localization of the damage.

[0032] The one in the Fig. The acceleration sensor 150 provided in the embodiment shown in Figure 1 is optional and is arranged on the outer wall of the battery housing 110. Alternatively, the acceleration sensor 150 can again be arranged within the battery housing 110. Furthermore, it can be advantageous if several acceleration sensors 150 are arranged on the battery housing 110, again to create redundancy.

[0033] The battery case diagnostic device 170 further includes a controller 160. The controller 160 may include a processor and a memory. Alternatively, the controller 160 may be the processor coupled to the memory. The processor may be a central processing unit (CPU). The processor may further be another general-purpose processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or another programmable logic device, a discrete gate or transistor logic device, a discrete hardware component, or the like. The general-purpose processor may be a microprocessor, or the processor may be any conventional processor or the like.

[0034] Memory includes, but is not limited to, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), or portable read-only memory (e.g., CD-ROM). The memory is configured to store associated program instructions and associated data.

[0035] The control device 160 has, in the embodiment of the Fig. 1, a first control device section 162, a second control device section 164, a third control device section 166, a fourth control device section 168, a fifth control device section 167 and a sixth control device section 169, which will be described further below with reference to the Fig. 2 will be discussed in more detail. At this point, however, it should only be noted that the fifth control device section 167 and the sixth control device section 169 are optional.

[0036] With reference to the Fig. 2 is an exemplary flow diagram of a method according to the invention for determining damage to the battery housing 110 of the Fig. 1 shown.

[0037] The procedure of Fig. 2 starts at step 200 and then proceeds to step 210, where an acceleration of the battery housing 110 is detected by means of the acceleration sensor 150. The control device 160, in particular the fifth control device section 167, can receive the acceleration signal from the acceleration sensor 150.

[0038] In a further step 220, a check is performed to determine whether the acceleration signal received in step 210 indicates an acceleration value of the battery housing 110 that exceeds a predetermined acceleration threshold. If it is determined in step 220 that the acceleration value determined from the received acceleration signal does not exceed the predetermined acceleration threshold, the method proceeds to step 280 and is terminated. The evaluation of the acceleration signal can be performed by the control device 160, in particular the sixth control device section 169.

[0039] However, if it is determined in step 220 that the acceleration value determined from the received acceleration signal exceeds the predetermined acceleration threshold, the method proceeds to step 230, at which the control device 160, in particular the first control device section 162, sends a diagnostic signal to the ultrasonic device 140, in particular the ultrasonic transmitter 142. The diagnostic signal sent by the control device 160, in particular the first control device section 162, causes the ultrasonic device 140, in particular the ultrasonic sensor 142, to couple a predetermined ultrasonic signal into the wall of the battery housing 110. As already mentioned, the ultrasonic device 140, in particular the ultrasonic transmitter 142, excites the wall of the battery housing 110 with ultrasonic waves. The predetermined ultrasonic transmission signal has a predetermined frequency.Alternatively or additionally, several ultrasonic transmission signals with different frequencies can be coupled into the wall of the battery housing 110 at the same time.

[0040] In a subsequent step 240, the control device 160, in particular the second control device section 164, receives a response signal from the ultrasonic device 140, in particular from the ultrasonic receiver 144. The ultrasonic response signal is the ultrasonic transmission signal coupled by the ultrasonic transmitter 142 into the wall of the housing 110, propagated through the wall of the battery housing 110 and received by the ultrasonic receiver 144, which transmits this as an ultrasonic response signal to the control device 160, in particular to the second control device section 164.

[0041] In a subsequent step 250, the control device 160, in particular the third control device section 166, determines whether damage to the battery housing 110 is present. If it is determined in step 250 that the received ultrasonic response signal deviates from a predetermined ultrasonic response signal by no more than a threshold value, the method proceeds to step 280 and is terminated. However, if it is determined in step 250 that the received ultrasonic response signal deviates from the predetermined ultrasonic response signal by more than the predetermined threshold value, the method proceeds to step 260, where damage to the battery housing 110 is determined or ascertained.

[0042] In a subsequent step 270, a damage signal is sent, preferably from the fourth control device section 168, wherein the damage signal indicates that damage to the battery housing 110 has been detected. The method then terminates at step 280.

[0043] The present invention takes advantage of the fact that, initially during vehicle operation, a diagnosis of the battery housing 110 for damage can be performed upon the occurrence of an acceleration greater than a predetermined acceleration value, which can be detected by the acceleration sensor 150. This diagnosis can preferably be performed when the vehicle is stationary, for example, while the vehicle is parked.

[0044] Furthermore, it may be advantageous for the battery housing diagnostic device 170 to have a temperature sensor configured to generate a temperature signal representative of the ambient temperature of the vehicle. The inventive diagnosis of the battery housing 110 with regard to damage preferably occurs when the temperature signal indicates an ambient temperature of the vehicle that lies within a predetermined temperature range. This ensures that the temperature-dependent vibration behavior of the battery housing 110 is unaffected. This allows the comparisons of the ultrasonic response signals with the predetermined ultrasonic response signal to be performed reliably.

[0045] Furthermore, it is advantageous that the acceleration sensor 150 only needs to detect the acceleration of the battery housing 110 essentially qualitatively, whereby the quantity of the detected acceleration is not of great importance. A more precise check to determine whether damage to the battery housing 110 due to abnormal acceleration of the battery housing 110 actually exists can then be performed using the method according to the invention.

[0046] Additionally or alternatively, by evaluating the ultrasonic response signal, it can also be determined whether there is an excessive amount of water within the battery housing 110.

Claims

[1] Method for determining damage to a battery housing (110) of a battery device (100) for a vehicle, which battery device accommodates a battery arrangement (120), wherein an ultrasonic device (140) is provided which is designed to couple at least one ultrasonic transmission signal into the wall of the battery housing (110) and to receive the at least one ultrasonic transmission signal propagated through the wall of the battery housing (110) as an ultrasonic response signal, the method comprising: - transmitting a diagnostic signal which causes the ultrasonic device (140) to couple at least one predetermined ultrasonic transmission signal into the wall of the battery housing (110), - receiving an ultrasonic response signal from the ultrasonic device (110), the ultrasonic response signal being representative of the ultrasonic signal received by the ultrasonic device (140) in response to the coupling of the predetermined ultrasonic transmission signal into the wall of the battery housing (110), - Determining damage to the battery case (110) if the received ultrasonic response signal deviates from a predetermined ultrasonic response signal by more than a threshold value, and - Sending a damage signal when damage to the battery housing (110) has been detected, the damage signal indicating that damage to the battery housing (110) has occurred. [2] The method of claim 1, wherein the predetermined ultrasonic transmission signal has at least one predetermined frequency. [3] Method according to one of the preceding claims, wherein determining damage to the battery housing (110) comprises: - Determining an attenuation between the predetermined ultrasonic transmission signal and the received ultrasonic response signal, and - Determining damage to the battery casing if the determined attenuation deviates from a predetermined attenuation value by more than a attenuation threshold value. [4] Method according to one of the preceding claims, wherein the harmonic spectrum of the ultrasonic response signal is evaluated when determining damage to the battery housing (110). [5] Method according to one of the preceding claims, wherein an acceleration sensor (150) is further arranged on the battery housing (110) and is designed to send an acceleration signal that is representative of an acceleration of the battery housing (110), the method further comprising: - receiving an acceleration signal from the acceleration sensor (150), and - Determining that the received acceleration signal indicates an acceleration value that exceeds a predetermined acceleration threshold, wherein determining damage to the battery case (110) is based at least in part on determining that the received acceleration signal indicates an acceleration value that exceeds a predetermined acceleration threshold. [6] Control device (160) adapted to carry out the steps of the method according to any one of the preceding claims. [7] Control device (160) according to claim 6, comprising: - a first control device section (162) for carrying out the step of sending the diagnostic signal to the ultrasound device (), - a second control device section (164) for performing the step of receiving the ultrasonic response signal from the ultrasonic device (), - a third control device section (166) for carrying out the step of determining damage to the battery case (), and - a fourth control device section (168) for carrying out the step of transmitting the damage signal. [8] Control device (160) according to claim 7, further comprising: - a fifth control device section (167) for performing the step of receiving an acceleration signal from the acceleration sensor (), and - a sixth controller section (169) for performing the step of determining that the received acceleration signal indicates an acceleration value that exceeds a predetermined acceleration threshold. [9] Battery case diagnostic device (170), comprising: - an ultrasonic device (140) which is designed to be attached to a battery housing (110) of a battery device (100) for a vehicle, wherein the ultrasonic device (140) is further designed to couple at least one ultrasonic transmission signal into the wall of the battery housing (110) and to receive the at least one ultrasonic transmission signal propagated through the wall of the battery housing (110) again as an ultrasonic response signal, and - a control device (160) according to one of claims 6 to 8. [10] Battery case diagnostic device (170) according to claim 9, further comprising: - an acceleration sensor (150) configured to be attached to the battery housing (110), wherein the acceleration sensor (150) is further configured to transmit an acceleration signal representative of an acceleration of the battery housing (110). [11] Battery device (100) for a vehicle, comprising - a battery housing (110), - a battery arrangement (120) arranged in the battery housing (110), and - a battery case diagnostic device (170) according to one of claims 9 and 10. [12] A vehicle having a battery device (100) according to claim 11. [13] A computer program comprising instructions which, when executed by a computing unit, cause the computing unit to carry out a method according to any one of claims 1 to 5. [14] A computer-readable medium on which the computer program according to claim 13 is stored.

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