Battery pack; system with a first battery pack and a second battery pack; consumer with one battery pack

Abstract

The invention relates to a battery pack, in particular a replaceable battery pack for an electric bicycle, with electronics, wherein the electronics comprise at least one printed circuit board (PCB) on which a control module, a power switch module, and a current sensing module are arranged, the control module comprising at least one processing unit, in particular a microcontroller. It is proposed that the control module comprise at least one ASIC, wherein at least six of the following functions are integrated into the at least one ASIC: a cell voltage monitoring function, a cell balancing function, a current measurement function, a control or regulation function for external compute / digital fetched transistors (CFTs), a power supply function, a communication transceiver, a pre-charging circuit, a temperature sensing function, a wake-up function, and a charge level indicator control function.

Description

Prior ArtReplaceable battery packs having different geometries for electric bicycles have already been described, for example in DE 10 2023 200 210 A1 and in DE 10 2020201165 A1.Disclosure of the InventionThe invention relates to a rechargeable battery pack, in particular a replaceable rechargeable battery pack for an electric bicycle, having electronics, wherein the electronics have at least one printed circuit board, wherein a control module, a circuit breaker module and a current detection module are arranged on the printed circuit board, wherein the control module has at least one arithmetic unit, in particular a microcontroller. It is proposed that the control module has at least one ASIC, wherein at least six of the following functions are integrated in the at least one ASIC: a cell voltage monitoring function, a cell balancing function, a current measurement function, a control or regulating function for, in particular, external c / dFETs, a power supply function, a communication transceiver, a pre-charge circuit, a temperature detection function, a wake-up function, a charge state indication control function. Advantageously, a battery pack with modular and compact electronics can thereby be provided.In the context of this application, an electric bicycle is to be understood to mean, in particular, a bicycle which has a drive unit for assisting the rider. The electric bicycle is preferably designed as an e-bike, a pedelec, an s-pedelec, a cargo bicycle, a folding bicycle or the like. The drive unit has a motor which can be designed, for example, as a central motor or as a hub motor. The motor is preferably designed as an electric motor. The drive unit is connected to the battery pack for supplying the drive unit with energy. The battery pack has a battery housing which is preferably detachably connected to a housing of the consumer, in particular to a frame of the electric bicycle. The electric bicycle preferably has a control unit, wherein the control unit of the electric bicycle is assigned to the electronics.The electronics of the battery pack comprise a multiplicity of electronic components which are arranged on one or more printed circuit boards. The printed circuit boards can be designed as a rigid printed circuit board or as a flexible printed circuit board. The electronics of the battery pack can have, in addition to the printed circuit board, a computing unit, a control unit, a transistor, a capacitor, and / or a storage unit. The electronics are designed for controlling or regulating the battery pack and / or the load. The electronics comprise in particular a BMS (engl. Battery Management System), which is designed to monitor the battery pack. The BMS is designed, in particular, to prevent overcharging and / or deep discharge of the battery pack. The BMS is preferably designed for correct cell balancing. The battery pack can also have one or more sensor elements, for example a temperature sensor for determining the temperature within the battery pack or a motion sensor for determining movements. In addition, the battery pack can comprise at least one communication interface for wirelessly connecting the battery pack to a mobile terminal and / or a server and / or the electric bicycle. The communication interface can be designed, for example, as a short-range communication interface, in particular as a Bluetooth interface or as a WiFi interface, for connection to the mobile terminal.As a replaceable battery pack, the battery pack is preferably designed to be detachable with the electric bicycle without tools. Alternatively, it is also conceivable for the battery pack to be fixedly attached or integrated in the housing of the electric bicycle. A tool-free separation is also to be understood here as a separation via a lock, for example a bicycle lock. The lock can be designed to be actuatable, for example, via a key or an electric actuator. The battery pack is in particular configured such that it can be connected to a charging device for charging the battery pack. Alternatively or additionally, the battery pack can also be designed in such a way that it can be charged in the state connected to the electric bicycle.The battery pack comprises in particular a housing. At least one battery cell is arranged in the housing of the battery pack. The housing of the battery pack is preferably designed as an outer housing. The battery pack, in particular the housing of the battery pack, can be configured to be detachably connectable or fixedly connected to the load, in particular to the electric bicycle, and / or a charging device, via a mechanical interface. The housing preferably has at least one housing part which is designed as an outer housing part. The outer housing part in this case delimits the battery pack on the outside and can be touched by a user.In addition, the battery pack has at least one electrical interface for electrical connection to a load, preferably a load in the form of the electric bicycle. The battery pack is designed to be electrically connectable to the load via the electrical interface. The battery pack can be charged and / or discharged, for example, via the electrical connection. Alternatively or additionally, it is also conceivable that information can be transmitted from the battery pack to the load and vice versa via the electrical interface. The load or the charger has an electrical interface corresponding to the electrical interface of the battery pack.The electrical interface is preferably designed as a contact interface in which the electrical connection is effected via a physical contact of at least two conductive components. The electrical interface preferably comprises at least two electrical contact elements. In particular, one of the electrical contact elements is designed as a positive contact and the other electrical contact element is designed as a negative contact. In addition, the electrical interface can have at least one additional contact which is designed to transmit additional information to the electric bicycle and / or to the charging device. The additional contacts can be designed as signal contacts, coding contacts, temperature contacts, bus contacts, etc. The electrical contact elements can be designed, for example, as resilient contact elements in the form of contact tulips or as flat contacts in the form of contact blades. Alternatively or additionally, the electrical interface can have a secondary charging coil element for inductive charging. The mechanical interface and the electrical interface can be integrated or formed separately from one another.The battery cell can be designed as a galvanic cell which has a structure in which one cell pole comes to lie at one end and a further cell pole comes to lie at an opposite end. In particular, the battery cell has a positive cell pole at one end and a negative cell pole at an opposite end. The battery cells are preferably designed as NiMn or NiMn cells, particularly preferably as lithium-based battery cells or Li-ion battery cells. Alternatively, it is also conceivable, for example, for the rechargeable battery cell to be designed as a pouch cell or as a prismatic cell. The battery voltage of the battery pack is generally a multiple of the voltage of an individual battery cell and results from the circuit (parallel or serial) of the battery cells. In the case of conventional battery cells having a voltage of 3.6 V, this results in an example battery voltage of 3.6 V, 7.2 V, 10, 8 V, 14.4 V, 18 V, 36 V, 54 V, 108 V, etc. The battery cell is preferably designed as an at least substantially cylindrical round cell, the cell poles being arranged at ends of the cylindrical shape.An ASIC (application-specific integrated circuit) is to be understood in the context of this application as an integrated circuit which is designed for a specific application. The ASIC is configured to perform a predefined set of functions. Preferably, the control module comprises a single ASIC.The cell voltage monitoring function is in particular designed to monitor the voltage preferably of each individual battery cell of the battery pack.The cell balancing function is in particular configured to balance the charge between the battery cells and preferably to ensure that the battery cells are substantially uniformly discharged and / or discharged.The current measurement function is designed, in particular, to measure the current that flows through the system, in particular through the ASIC. The current measurement function of the ASIC is preferably designed to detect performance data and / or overloads.The control function for external c / dFETs is designed for controlling or regulating external field effect transistors which are arranged on the power switch module.The power supply function is designed to provide a supply voltage for at least the microcontroller of the control module.The communication transceiver is configured for communication with other components. The communication transceiver can be designed, for example, as a CAN transceiver, in particular as a CAN FD transceiver.The precharge circuit is designed for precharging external capacitors.The temperature detection function is designed to detect a temperature characteristic variable of the battery pack.The wake-up function is in particular designed to activate the battery pack from a rest state, preferably based on external signals or communication requests which are received by way of example by means of the communication transceiver.The state-of-charge indicator control function is designed to control a state-of-charge indicator, in particular a state-of-charge indicator of the battery pack. The state of charge indicator may be designed to indicate a state of charge of the battery pack and / or to indicate fault codes.Furthermore, it is proposed that all functions are integrated in the ASIC. Advantageously, the required installation space can thereby be further reduced.It is furthermore proposed that the power switch module has a cFET and / or a dFET. The power switch module is in particular designed as a switch which is designed to control the main power supply of the battery pack. In the context of this application, a cFET is to be understood as meaning, in particular, a transistor which controls the charging process. In the context of this application, a dFET is to be understood as meaning, in particular, a transistor which controls the discharge process.It is also proposed that the battery pack has two power switch modules, wherein the power switch modules are preferably connected to one another in parallel. Advantageously, the electronics can thereby be adapted to the performance of the battery pack by the number of power switch modules.Furthermore, it is proposed that the battery pack according to one of the preceding claims, characterized in that the current detection module has at least one shunt resistor. Alternatively, it is also conceivable for the current detection module to be implemented as one or more Hall-effect sensors or current transformers.It is furthermore proposed that the battery pack has at least two current detection modules, wherein the current detection modules are preferably connected to one another in parallel. Advantageously, the number of current detection modules can thereby adapt the electronics to the performance of the battery pack.It is also proposed that the control module is connected to the circuit breaker module and the current detection module via signal lines, wherein the signal lines each end on at least two sides of the control module, in particular orthogonal and / or opposite sides of the control module. Advantageously, the modularity can be increased as a result.Furthermore, the invention relates to a system, having a first battery pack as described above and a second battery pack as described above, wherein the circuit breaker module and the current detection module have a first configuration relative to one another in the first battery pack and a second configuration relative to one another in the second battery pack with respect to the control module. Advantageously, the same modules can thereby be used for different battery packs with different geometric requirements. In particular, the power switch modules, the current detection modules and the control modules of the first battery pack and of the second battery pack are substantially identical.It is furthermore proposed that the second battery pack has a different number of power switch modules and / or current detection modules. Advantageously, the same modules can thereby be used for battery packs with different performance capabilities.In addition, the invention relates to a load with a battery pack as described above. The load can also be designed as another light-weight electric vehicle, for example as an e Or as an electric motorcycle. It is likewise conceivable for the consumer to be designed as a garden appliance, as a domestic appliance or as a hand-held power tool. The consumer can have a single battery pack or a plurality of battery packs and also different battery packsDRAWINGSFurther advantages are evident from the following description of the drawings. The drawings, specification and claims contain numerous features in combination. The skilled person will expediently also consider the features individually and summarize them to form meaningful further combinations.The following are shown: FIG. 1 shows a perspective view of an electric bicycle with a battery pack; FIG. 2 ashows a perspective view of a battery pack for the electric bicycle according to FIG. 1 ; FIG. 2 b is a schematic view of a control module; FIG. 2 cshows a schematic view of a current detection module; FIG. 2 d is a schematic view of a circuit breaker module; FIG. 2 e shows a printed circuit board with electronics for the battery pack according to FIG. 2 a; FIG. 3 ashows a perspective view of a further battery pack for the electric bicycle according to FIG. 1 ; FIG. 3 bshows a printed circuit board with electronics for the battery pack according to FIG. 3 a; FIG. 4 ashows a perspective view of a second battery pack for the electric bicycle according to FIG. 1 ; FIG. 4 bshows a printed circuit board with electronics for the battery pack according to FIG. 4 a.DESCRIPTION OF THE EMBODIMENTSFIG. 1 shows a load 10 with an energy supply device 100 in the form of a battery pack 102 in a perspective view. The load 10 is designed, for example, as an electrically driven means of transportation 12, in particular as an electric bicycle 14. The electric bicycle 14 can be designed, for example, as a pedelec or as an e-bike.The electric bicycle 14 has a frame 18. Two wheels 20 are connected to the frame 18. In addition, the consumer 10 has a drive unit 22, which comprises an electric motor. The electric motor is preferably designed as a permanent magnet-excited brushless direct current motor. The electric motor is designed as a central motor, for example, wherein a hub motor or the like is also conceivable.The drive unit 22 comprises a control unit (not shown) which is designed for controlling or regulating the electric bicycle 14, in particular the electric motor. The electric bicycle 14 has a pedal crank 24. The crank 24 is connected to a crank shaft (not shown).The control unit and the drive unit 22 with the electric motor and the pedal crank shaft are arranged in a drive housing 26 connected to the frame. The drive movement of the electric motor is preferably transmitted to the crankshaft via a transmission (not shown), wherein the amount of assistance by the drive unit 22 is controlled or regulated by means of the control unit.The electric bicycle 14 is electrically and mechanically connected to the battery pack 102 which is designed to supply energy to the drive unit 22. The battery pack 102 is designed, for example, as a replaceable battery pack. The battery pack 102 is, for example, completely accommodated in the frame 18 of the electric bicycle 14 in the connected state. The connection can be effected by axially pushing the battery pack 102 into the down tube of the frame 18 or by pivoting the battery pack 102 laterally into the frame 18. Alternatively, it is also conceivable that the battery pack 102 is designed such that the battery pack 102 can be fastened to an outer side of the frame 18.The battery pack 102 is shown in FIG. 2 ain a perspective view and corresponds to a first battery pack 101. The battery pack 102 has a housing 104, in which 30 battery cells are arranged, for example. The housing 104 is formed in multiple parts by way of example and has a tubular main body 110 which is formed from a metal part by way of example. At the end face, the housing 104 has two end plates 108, which are designed as connection plates 112 and each have at least one connecting element 116. The connecting elements 116 are assigned to a mechanical interface of the battery pack 102, which is designed for the mechanical connection of the battery pack 102 to the electric bicycle 14. The connecting elements 116 are formed, for example, as recesses in the connection plate 112, in which recesses a corresponding connecting element, not shown, of the electric bicycle 14 can engage. The tubular base body 110 additionally has, on its side surfaces, in each case, for example, two longitudinal grooves 105, which can likewise be assigned to the mechanical interface, for example, or can be used, for example, for connection to a cover.In addition, the battery pack 102 has a state-of-charge indicator 106. The charge state indicator 106 is connected to an electronics unit 200 (see FIG. 2 e ) of the battery pack 102, which is arranged in the housing 104 of the battery pack 102. The charge state indicator 106 can be configured to be actuatable by the user via a button press or automatically actuatable.Furthermore, the battery pack 102 comprises an electrical interface 114 for electrically connecting the battery pack 102 to the electric bicycle 14. The electrical interface 114 comprises, for example, four electrical contact elements, wherein two electrical contact elements are designed as power contacts and at least one electrical contact element is designed for exchanging information between the battery pack 102 and the electric bicycle 14.The electronics 200 of the battery pack 102 are assigned a control unit with a monitoring system, for example a BMS, for monitoring the battery pack 102, in particular the battery cells. The battery cells are monitored in terms of their voltage by means of a single-cell monitoring system and their temperature by means of a temperature sensor (not shown). The electronics 200 of the battery pack 102 are connected to the electronics or the control unit of the electric bicycle 14 via the electrical interface 114.The electronics 200 of the battery pack 102 includes a control module 202, a power switch module 204, and a current sensing module 206. The modules are designed in such a way that they are designed such that they can be connected to one another in different configurations to form the electronics. The modules are advantageously designed in such a way that the electronics can be optimally adapted to the battery pack 102 by the respective arrangement of the modules with respect to one another or by the number of modules.In FIG. 2 b, the control module 202 is shown in a schematic view. The control module comprises an ASIC 208 and a computing unit 210 in the form of a microcontroller 212. Here, the following functions of the electronics 200 are integrated in the ASIC 208 by way of example: a cell voltage monitoring function, a cell balancing function, a current measurement function, a control or regulating function for c / dFETs, a power supply function, a communication transceiver, a pre-charge circuit, a temperature detection function, a wake-up function, a state-of-charge indication control function. However, it would likewise be conceivable for individual functions not to be integrated in the ASIC.In addition, the control module 202 includes a plurality of signal and / or voltage lines configured to connect to the other modules. The signal and / or voltage lines are arranged in such a way that they end on at least two sides, for example on four sides of the control module 202, so that the further modules can be connected to the control module 202 on different sides. By way of example, five signal and / or voltage lines are shown, a first signal and / or voltage line 214, a second signal and / or voltage line 216, a third signal and / or voltage line 218, a fourth signal and / or voltage line 220 and a fifth signal and / or voltage line 222. However, other numbers of signal and / or voltage lines are also conceivable, this being determined by the requirement of the electronics. These are in each case individual signal and / or voltage lines, which however end on different sides, so that a connection to the signal and / or voltage line on different sides is possible. The electronics 200 preferably have a multilayer printed circuit board 224 (cf. FIG. 2 e), so that the signal and / or voltage lines running horizontally and / or vertically do not intersect on one plane.In FIG. 2 c, the current detection module 206 is shown in a schematic view. The current detection module 206 has, by way of example, a current detection element 226 in the form of a shunt resistor 228.In addition, the current sensing module 206 includes a plurality of signal and / or voltage lines configured to connect to the control module 202 and / or the power switch module 204 and / or another current sensing module 206. Five signal and / or voltage lines 214', 216', 218', 220', 222' are shown by way of example.The current detection module 206 is preferably arranged in a power (+) path of the electronics 200.In FIG. 2 d, the circuit breaker module 204 is shown in a schematic view. The power switch module 204 illustratively includes a cFET 230 and a dFET 232 that are driven by the control module 202 when connected.In addition, the power switch module 204 includes a plurality of signal and / or voltage lines configured to connect to the control module 202 and / or the current sensing module 206 and / or another power switch module 204. Five signal and / or voltage lines 214", 216", 218", 220", 222" are shown by way of example.The power switch module 204 is preferably arranged in a power (-) path of the electronics 200.In FIG. 2 e, the electronics 200 of the battery pack 102 with the multilayer printed circuit board 224 is schematically illustrated, wherein the printed circuit board 224 is populated with the control module 202, the power switch module 204 and the current detection module 206 in a first configuration 201.In this case, the first and second signal and / or voltage lines 214 of the control module 202 are connected to the first and second signal and / or voltage lines 214', 216' of the current detection module 206 and the third and fourth and fifth signal and / or voltage lines 218, 220, 222 of the control module 202 are connected to the third and fourth and fifth signal and / or voltage lines 218", 220", 222" of the power switch module 204.By way of example, in this view, the power switch module 204 and the current sensing module 206 are disposed on and connected to the right side of the control module 202. However, it would likewise be conceivable to arrange these on the left-hand side, since the left-hand side likewise has the necessary signal and / or voltage lines. The maximum length and width of the circuit board 224 is dictated by the geometry of the battery pack 102, such that an arrangement of the current sensing module 206 and the power switch module 204 above and / or below the control module 202 would not be possible. The printed circuit board 224 has, for example, a rectangular shape, wherein a longitudinal side 225 extends along a longitudinal extension 203 of the battery pack 102.FIG. 3 ashows a perspective view of a further battery pack 102 a. The battery pack 102 adiffers externally in particular by the length of the housing 104 a, which is caused by the number of battery cells accommodated in the housing 104 a. For example, battery pack 102 aincludes 50 battery cells. The two battery packs 102, 102 ain this case have the same operating voltage of 36 V, but differ in their capacity. By way of example, the two battery packs 102, 102 aare designed to be connectable to the electric bicycle 14 by means of the electrical and mechanical interfaces which are substantially identically designed. It is conceivable, for example, for the electric bicycle 14 to be supplied with energy by means of the first battery pack 101 or the further battery pack 102 aor by means of both battery packs 102, 102 a.The electronics 200 aand the printed circuit board 224 aof the further battery pack 102 aextend, as described above, parallel to the longitudinal extent 203 aof the battery pack 102 a. Due to the larger installation space of the battery pack 102 arelative to the first battery pack 101, a longer printed circuit board 224 ais also possible and provided in this case.FIG. 3 b shows the electronics 200 aof the further battery pack 102 ain a schematic view. The electronics 200 aincludes a multilayer printed circuit board 224 aon which a control module 202 a, two current detection modules 206 a, and two power switch modules 204 aare arranged and connected to each other. The control module 202 a, the current detection modules 206 aand the power switch modules 204 aof the electronics 200 ain this case substantially correspond to the control module 202 a, the current detection module 206 and the power switch module 204 of the first battery pack 101.The two current detection modules 206a are connected to one another via the first and second signal and / or voltage lines 214a', 216a'. The two power switch modules 204 are interconnected via the third, fourth and fifth voltage lines 218a", 220a", 222a". The modules are connected in parallel by way of example.Due to the increased number of current detection modules 106 aand circuit breaker modules 204 a, the further battery pack 102 acan be optimally adapted to its performance. By using the same modules, the adaptation of the electronics 200 ain comparison to the electronics 200 of the first battery pack 101 can advantageously take place without a complete redesign of the electronics.FIG. 4 ashows a battery pack 102 b, in particular a second battery pack 101 bin a perspective view. The second battery pack 101 bhas a housing 104 bwhich is shorter and wider compared to the battery packs 102, 102 adescribed above. The electrical interface 114 bcorresponds to the above-described electrical interfaces 114 so that the second battery pack 101 bcan also be connected to the electric bicycle 14, preferably the second battery pack 101 bas an additional battery pack 102 bfor increasing the range of the electric bicycle 14 in addition to one of the above-described battery packs 102, 102 a. The second battery pack 101 bhas 20 battery cells, for example.In order to ensure the shortest possible housing 104 bof the second rechargeable battery pack 101 b, the printed circuit board 224 bof the electronics 200 bof the second rechargeable battery pack 101 bis arranged perpendicular to the longitudinal extent 203 bof the rechargeable battery pack 101 b.FIG. 4 bshows a schematic view of the printed circuit board 224 bof the second battery pack 101 b. The electronics 200 bof the second battery pack 101 bincludes a control module 202 b, a current detection module 206 band a power switch module 204 bwhich are designed to be substantially the same as the modules of the first battery pack 101.With this arrangement, the circuit board 224 bhas a size that does not allow the modules in the first configuration 201 to be arranged. Thus, the control module 202 b, the current sensing module 206 band the power switch module 204 bof the electronics 200 bare arranged in a second configuration 201 b.By way of example, the current sensing module 204 band the power switch module 204 bare connected to the control module 202 bon different, in particular opposite, sides thereof.References included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedDE 10 2023 200 210 A1

[0001] DE 10 2020201165 A1

[0001]

Claims

Battery pack, in particular a replaceable battery pack for an electric bicycle (14), having an electronics unit (200), wherein the electronics unit (200) has at least one printed circuit board (224), wherein a control module (202), a power switch module (204) and a current detection module (206) are arranged on the printed circuit board (224), wherein the control module (202) has at least one arithmetic unit (210), in particular a microcontroller (212), characterized in that the control module (202) has at least one ASIC (208), wherein at least six of the following functions are integrated in the at least one ASIC: a cell voltage monitoring function, a cell balancing function, a current measurement function, a control or regulation function for external c / dFETs, a power supply function, a communication transceiver, a precharge circuit, a temperature detection function, a wake-up function, a state of charge indication control function.Battery pack according to Claim 1, characterized in that all functions are integrated in the ASIC (208).Battery pack according to one of the preceding claims, characterized in that the power switch module (204) has a cFET (230) and / or a dFET (232).Rechargeable battery pack according to one of the preceding claims, characterized in that the rechargeable battery pack (102a) has two power switch modules (204a), the power switch modules (204a) preferably being interconnected in parallel with one another.Battery pack according to one of the preceding claims, characterized in that the current detection module (206) has at least one shunt resistor (228).Rechargeable battery pack according to one of the preceding claims, characterized in that the rechargeable battery pack (102a) has at least two current detection modules (206a), the current detection modules (206a) preferably being interconnected in parallel with one another.Battery pack according to one of the preceding claims, characterized in that the control module (202) is connected to the power switch module (204) and the current detection module (206) via signal lines (214, 216, 218, 220, 222), wherein the signal lines (214, 216, 218, 220, 222) each end at at least two sides of the control module (202), in particular orthogonal and / or opposite sides of the control module (202).System, comprising a first battery pack (101) according to Claim 1 and a second battery pack (101b) according to Claim 1, characterized in that the circuit breaker module (204) and the current detection module (206) have a first configuration (201) in the first battery pack (101) and a second configuration (101b) relative to one another in the second battery pack (101b) with respect to the control module (202).The system according to claim 8, characterized in that the second battery pack (101b) comprises a different number of power switch modules and / or current detection modules.Load with a battery pack according to Claim 1 or with a system according to Claim 8.

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