Battery device for providing three-phase alternating current independently of location

Abstract

The invention relates to a battery device for providing three-phase alternating current independently of location, comprising a housing with three-phase alternating current output. The housing accommodates one or more battery packs, a bidirectional three-phase inverter and one or more common-mode filters. The housing encloses one or more heatsinks with a heat-dissipating surface for dissipating waste heat to the ambient air. The energy density of the battery device in relation to its residual weight, which corresponds to the total weight of the device minus the weight of the battery pack or, in the case of a plurality of battery packs, their total weight, thus the gross capacity of one or, in the case of a plurality of battery packs, of all battery packs, is at least 0.1 kWh / kg. Advantageously, the device includes a high-voltage battery. The device can be designed as a hand-drawn trolley (3), having wheels and support feet for parking the device in a horizontal position of the housing on level ground. In the embodiment as a hand-drawn trolley (3), a lifting handle, such as a fold-out handle bar (18), is provided on the device. Advantageously, the total weight of the device is less than 100 kg.

Description

Battery device for making three-phase alternating current available regardless of location

[0001] The invention relates to an accumulator device, or accumulator device for short, for making three-phase alternating current available in a location-independent manner, which provides at least one connection for a three-phase consumer in the form of a three-phase alternating current output.

[0002] Portable power supply units with a connection for single-phase loads are known in the prior art. The capacities of the battery packs installed in such power supply units are typically in the range of approximately 2-5 kWh. Accordingly, these devices, although portable, have limited applicability, as the available capacities are insufficient for power-intensive applications.

[0003] For many household and office applications, standard mains voltage is perfectly adequate because single-phase appliances can be used. However, this is usually not the case in trade or industry. Here, tools, motors, machines, and equipment require more power from the electrical supply; that is, they depend on three-phase alternating current. These are therefore referred to as three-phase loads, with a significantly higher RMS voltage. In professional applications, typically in construction, trade, industry, event technology, film technology, emergency services, etc., power-hungry loads are generally used, which must be operated with three-phase alternating current.

[0004] State-of-the-art power supply units for providing three-phase alternating current are very heavy, making them impossible to move by hand. Loading and unloading such units is not possible manually. They are usually designed as stationary charging stations or are stored in vehicles, typically light trucks or trailers. A significant portion of the weight of such heavy power supply units is attributable to their cooling systems. Because batteries with high capacities and power outputs require greater cooling capacity, these battery systems are often water-cooled. Aside from the disadvantage of the weight, water cooling systems are also prone to failure and require more maintenance. Furthermore, batteries with high capacities and power outputs exhibit poorer electromagnetic compatibility (EMC) due to the presence of noise and interference signals.

[0005] Against this background, the object of the present invention is to provide a handy, i.e., lightweight, battery device for making three-phase alternating current available regardless of location, which can then be used effectively for high-power, three-phase consumers. This is intended, in particular, to open up the professional application area for mobile battery devices.

[0006] This problem is solved by a battery device according to the features of independent claim 1. Further advantageous variants of this battery device and their use are specified in the dependent claims.

[0007] The battery device according to the invention is described with reference to exemplary embodiments in the following figures. These show: Figure 1: The mobile battery device with the lifting handle extended; Figure 2: The mobile battery device according to Figure 1 in a perspective view from below; Figure 3: The mobile battery device with a fold-out lifting handle, with the lifting handle folded in; Figure 4: The mobile battery device according to Figure 3 with the lifting handle unfolded as it is pulled by a person; Figure 5: The mobile battery device in a view of the front of the housing with the outputs for connecting electrical consumers; Figure 6: The mobile battery device without wheels in a perspective view of the front with the outputs for connecting electrical consumers; Figure 7: The mobile battery device with wheels in a perspective view of the side with the wheels and the cooling surface; Figure 8: The mobile battery device without wheels, looking at the side with the heat sink, with the cooling fins projecting inwards; Figure 9: A cross-section through the heat sink of the battery device with its multitude of structured cooling fins; Figure 10: The internal structure of the mobile battery device with heat sink; Figure 11: The internal structure of another embodiment of the mobile battery device with heat sink; Figure 12: A circuit diagram to explain the power electronics installed in the mobile battery device; Figure 13: The mobile battery device in a perspective view without the top panel and side walls of its housing to reveal its internal components; Figure 14: A view of the internal components of the mobile battery device on the side facing away from the side shown in Figure 13; Figure 15: A view of the circuit boards as they are to be screwed onto the rear panel of the mobile battery device; Figure 16: A view of the circuit boards mounted in the mobile battery device; Figure 17a-g: The mobile battery device with support rails and in another version with wheels and support feet.

[0008] Figure 1 shows a perspective view of an embodiment of the battery device for providing three-phase alternating current independently of location. This mobile device comprises a substantially cuboid housing 1, the uppermost part of which is chamfered upwards. Alternatively, the housing can be chamfered (e.g., additionally) at the bottom or be purely cuboid. A battery pack is housed in the housing 1; the internal components of the device will be discussed later. Typical dimensions of the housing 1, excluding any lifting handles, are no more than 900 mm for length (L), no more than 400 mm for width (B), and no more than 600 mm for height (H). Depending on the specific design, the length (L) can also be interpreted as height (H), or the height (H) as depth (T), namely in the case of a housing 1 designed as a square right prism. In the embodiment shown here, the battery device weighs onlyApproximately 80 kg. Two opposing lifting handles 4, 5 are arranged at the top of the housing 1 and along its broad sides, enabling comfortable lifting and carrying of the device. These lifting handles 4, 5 are designed as loop handles. They can be fixed or foldable on the housing 1. This allows the device to be lifted or carried to the required location by two men, each grasping a lifting handle 4, 5. Because it can be assumed that even an untrained person can lift a weight of approximately 80 kg, the device can also be carried by just one person in an emergency, with the weight distribution being optimally close to the body due to the arrangement of the lifting handles 4, 5. In any case, a preferred embodiment of the battery-powered device weighs less than 100 kg and can be moved by a single person.For a preferred size of the device housing 1, excluding the lifting handles 4, 5, the dimensions are in the range of [650, 800] mm x [250, 350] mm x [450, 550] mm (L x W x H), making the housing particularly easy to handle. Preferably, the housing 1 is made of a stainless alloy, e.g., aluminum, and / or of plastic. |

[0009] As a rule, the battery device is rolled for transport, for which purpose it is designed as a handcart 3 with at least one wheel 8, 9 on the housing 1. In the present embodiment, a wheel 8, 9 is arranged on each of two adjacent lower corner regions 10, 11 of the housing 1, and these wheels are connected to a common axle 7 about which the device can be tilted. In Figure 1, the battery device is shown resting on its wheels 8, 9 and on the support feet 11, 12 in the two adjacent corner regions at the front of the end face 15. On level ground, the handcart 3 thus assumes a stable position with the housing 1 in a horizontal position, for example, when it is connected to one or more loads for power supply. For tilting, lifting, and pulling the device, a pivotable or—as in the illustrated case—extendable lifting handle 6 is provided on the side of the support feet 12, 13.By arranging the wheels 8, 9 in the corner areas 10, 11, the weight distribution is optimized when lifting the device by the lifting handle 6.

[0010] For outdoor use of the battery device, e.g., in open terrain or on construction sites, a vertical distance between the base plate 2 of the housing 1 and the handcart 3 proves useful when placed on level ground. This allows the housing 1 to stand stably on its few support points 8, 9, 12, 13, even on uneven ground. This vertical distance is advantageously at least 10 cm.

[0011] It is understood that in alternative embodiments the device can also have more than two wheels 8, 9 or only a single wheel – similar to a single-wheeled wheelbarrow. The wheels 8, 9 or the single wheel can also be rotatably mounted directly on the housing 1. Furthermore, the device according to the invention can also be designed so that it can be pushed like a wheelbarrow. The lifting handles on the housing 1 are then advantageously arranged analogously to those of a wheelbarrow. The device can also have only one support leg or more than two support legs.

[0012] Figure 2 shows the handcart 3 in a perspective view from below, so that the lifting handle 6 with its plate 14 for tilting and pulling the device is visible. This plate 14, with the end-mounted handle attached to it, can be pulled out of the guide rail 16 by hand until it reaches its stop. In conjunction with the guide rail 16, the lifting handle 6 with its plate 14 is thus telescopically extendable. Preferably, when the plate 14 is fully inserted into the guide rail 16, the lifting handle 6 does not protrude from below the base plate 2 of the housing 1, or, in the case of support feet that slope forward, it does not protrude beyond them. This ensures that the handle is stored compactly and securely.In one version of the handcart 3, the plate 14 can be extended against a restoring force, thus ensuring that the lifting handle 6 is securely stowed when not in use, preventing objects from catching on it. It is understood that the plate 14 can also be implemented differently than shown here, for example, in the form of two or more parallel bars, e.g., square tubes. Also visible in the view according to Figure 2 are the two wheels 8, 9 on the housing, which are connected to it via the wheel axle 7.

[0013] Figure 3 shows another embodiment of the mobile battery device according to the invention in the form of a handcart 3, again in a perspective view. In contrast to the embodiment according to Figures 1 and 2, a fold-out handle 18 is used here for tilting and pulling the mobile battery device. In this embodiment, the handle 18 is designed so that it can be accommodated in a recess in the end face 15 of the battery device, preferably on the inside along the contour of the recess, and is as flush as possible with the edge of the end face 15. Thus, when folded, the handle 18 is optimally positioned to save space and cannot snag on any objects.

[0014] Figure 4 shows the mobile device according to Figure 3, as it is pulled or rolled on the ground by a person in a tilted position with the handle 18 fully extended. The unfolding movement of the handle 18 is indicated by an arrow. The handle 18 can also be unfolded against a spring force, for example. Because hinges are arranged on each end of the handle at the upper corners of the recess and are guided internally along its contour, the handle 18 provides a long lever arm that makes maximum use of the recess's height, thus minimizing the force required by the person. In an alternative embodiment, the handle 18 acts as the edge of the device's end face 15, maximizing the lever length and minimizing the force required by the person.

[0015] Figure 5 shows a mobile battery device in a view of the front face 15, revealing the switch plate 17. The outputs for connecting electrical loads are located on this plate. The device according to the invention is particularly suitable for supplying loads for power-intensive applications with three-phase alternating current, also known as three-phase power. For this purpose, the battery device has at least one three-phase output 19 for receiving a corresponding three-phase plug. The three-phase output 19 is identifiable by the relatively large hinged cover of the three-phase socket. As can be seen, three AC outputs, each with a single-phase socket, are arranged along the width of the switch plate 17. This makes the mobile battery device shown here suitable for supplying single-phase loads with electrical current. In this preferred embodiment, the switch plate 17 also features a pressure relief valve (located at the bottom right of the switch plate 17), an emergency stop switch positioned centrally, a mains connection for charging the device, and an optional connection for a photovoltaic system as an additional charging option. Preferably, the device itself includes a photovoltaic kit (PV kit) for charging its battery. The pressure relief valve acts as a safety mechanism, opening to release excess pressure in the battery before it can lead to dangerous situations such as explosions or fires.Advantageously, a display is arranged on the switch panel 17 to show information about the operation of the battery device. In this example, it is implemented as a touchscreen for operating the device and selecting settings, operating modes, and the like. Of course, the switches, sockets, displays, and all features for setting and / or maintenance can also be arranged or implemented in a switch panel 17 in alternative configurations and in varying numbers. In particular, the switch panel 17 can also have more than one three-phase output.

[0016] The integration of all outputs for the connections, switches, display, operating and setting modalities onto a single switch plate 17 within the housing 1 enables a particularly space-saving design. Preferably, this switch plate 17 is recessed into a recess in the end face 15 of the device, so that all its components, and preferably including any protective hinged covers on the sockets, are enclosed by the housing 1 or by the edge of the end face 15 and do not protrude.

[0017] Another variant of the mobile battery device according to the invention, without wheels, is shown in Figure 6. Instead of wheels 8, 9 and support feet, this embodiment is placed on support rails. This device is transported by one or more persons using the lifting handles 4, 5. It is suitable especially for applications where locomotion on wheels 8, 9 is not possible or is difficult or simply not necessary.

[0018] Figure 7 shows a perspective view of the side of the mobile battery device facing away from the front face 15, specifically the side with the wheels 8, 9. This side is particularly noteworthy for showing the externally visible part of the heat sink 21. The view focuses on the cooling surface 20 formed by the cooling fins. This surface area is the sum of the areas of the inwardly projecting cooling fins 22 (shown here only at their vertical end edges) and the other, unseen surfaces on the heat sink 12, through which waste heat is dissipated to the surrounding air. By appropriately dimensioning the heat sink 21 with a sufficiently large surface area, a fan to increase airflow through the cooling fins 22 and thus facilitate heat dissipation to the environment may be unnecessary.With this type of cooling for the battery device, no ventilation slots are required in the housing 1. This allows the housing to be completely closed, except for openings for outputs for consumers, switches, and communication interfaces, with the exception of any one-way outlets for a pressure relief valve and / or a rainwater outlet. Preferably, a hydraulic connection with a hose can be used for the rainwater outlet, allowing rainwater to flow in only one direction. Openings for one-way outlets are correspondingly small. In particular, the housing 1 can be dustproof. Advantageously, the housing 1 of the mobile battery device is completely closed except for the aforementioned openings. A small number of openings in the housing 1 also contributes to low noise emissions from the battery device.Furthermore, the more efficient the heat sink 21, the less power an additional fan, which is generally the largest source of noise emission in a battery device, needs to provide. In the best case, or with a suitably sized heat sink 21, a fan can even be dispensed with entirely. The absence of openings in the housing 1, apart from openings for outputs for consumers, switches, and communication interfaces, and for any one-way outlets, proves to be particularly advantageous for using the device according to the invention in damp and / or dusty locations, e.g., on construction sites or similar. In particular, the... The battery device should then be operated at a relative humidity of at least 95%. It is understood that the cooling variant shown here with heat sink 21 can be used on any version of the battery device, including, of course, a wheelless version as shown in Figure 6. In particular, the heat sink 21 can also be designed to form outwardly projecting cooling fins 22 on other sides of the battery device to increase the cooling surface 20.

[0019] To increase heat dissipation to the outside, minimal air vents can be incorporated into the housing. These vents are sized to allow the necessary cooling airflow to escape while drawing in fresh ambient air through other vents. These vents are designed to minimize the device's required classification for protection against foreign objects and contact, as well as protection against water. The vents are dimensioned so that a solid foreign object of a specific diameter cannot pass through them. Depending on the design, the vents provide protection against a solid foreign object whose diameter is typically one of the following values: {2.5 mm, 2.25 mm, 2 mm, 1.75 mm, 1.5 mm, 1.25 mm, 1 mm, 0.75 mm}.Apart from openings for consumer and switch outputs, the housing 1 of the battery device according to the invention can be completely enclosed except for minimal openings for air exchange and any openings for one-way outlets (such as a pressure relief valve or a rainwater outlet). In damp and / or dusty locations, it is advisable to install an air-permeable membrane or filter at the location of such cooling openings to keep water, dirt, and other foreign matter out.

[0020] Figure 8 shows the numerous inwardly projecting cooling fins 22 or cooling lamellae of the heat sink 21 on the side of the battery device facing away from the end face 15. The heat sink 21 is advantageously anodized, which allows it to dissipate more heat through thermal radiation due to the porosity of the surface. A black anodized layer leads to higher absorption of radiant heat due to its color. Black has the property of having a wider range of to absorb electromagnetic spectrum and convert it into heat. This further increases heat dissipation from the interior of the device due to radiation. The cooling fins 22 are advantageously integrally molded onto a rear plate as a rear cooling plate or at least connected with good thermal contact, the rear plate in turn being connected to the power electronics components, as will be explained later. Depending on the design and dimensions of the heat sink 21, e.g., with the cooling surface 20 extending to areas of the longitudinal sides of the device that connect at right angles to the side shown in Figure 8, a blower or fan can be completely omitted in the housing 1 of the device. The passive dissipation of waste heat via the heat sink 21 is then sufficient for cooling the device, so that, depending on the circumstances, no blower is necessary or only a low-volume fan is sufficient to support cooling.This means that the device according to the invention can be operated, charged, and discharged without or with very little background noise. This opens up areas of application in particular where even small background noises are especially disruptive, such as during music, sound, or speech playback.

[0021] Figure 9 shows a cross-sectional view of a preferred embodiment of the heat sink 21 with its fins 22 projecting perpendicularly from the back plate. It can be seen that the fins 22 are specially structured, namely corrugated, to increase the cooling surface area 20. Advantageously, the number of cooling fins 22 on the heat sink 21 is between 30 and 70. Preferred mass ranges are listed below: • m1 : [0.5 cm, 1 cm], • m2: [0.1 cm, 0.3 cm], • m3: [1.5 cm, 5 cm], • m4: [0.5 cm, 1.5 cm] • m5: [20 cm, 50 cm]. In one variant, the heat sink 21 is U-shaped with right angles so that it at least partially follows the contours of the housing. This further increases the cooling surface 20 for the most pronounced, or even entirely passive, cooling of the Battery device. Profile-shaped heat sinks 21 can be extruded and are therefore easy and inexpensive to manufacture. A battery device can also include several heat sinks 21 or a heat sink 21 with several individual components, which are advantageously connected to each other via thermal bridges. The weight of the heat sink 21 in the mobile battery device is preferably no more than 7.5 kg, and more preferably no more than 5 kg.

[0022] As previously described, the heat sink 21 can interact with a fan to achieve air circulation inside the housing. The resulting cooling of the battery device is a forced-air cooling system, whereby waste heat is passively dissipated to the outside, so that no exchange with the ambient air takes place. The internal structure of such a mobile battery device with heat sink 21 and fans 23 for forced-air cooling in the housing 1 is shown as an example in Figure 10. Here, the heat sink 21 consists of two components, each comprising a multitude of cooling fins 22 that provide a large cooling surface area, so that the two fans 23 used here each have a power consumption of at most 2 W, and advantageously even at most 1.5 W. In a preferred embodiment of the battery device, designed to minimize noise emissions, the presence of a fan 23 is completely omitted, and cooling is ensured solely by the heat sink 21.In principle, the higher the battery's capacity and current flow, the higher the required power of the fan 23. Figure 10 also shows the battery pack with its numerous battery cells 24, as well as two power modules 25, or component-populated circuit boards for the power converters. A power module, in this context, refers to a component-populated circuit board. The connections leading to the sockets on the front 15 of the housing 1 are not shown. The at least one three-phase output 19 for providing three-phase power regardless of location is clearly visible; such a device can have several of these outputs. The switch plate 17 is not shown.

[0023] Figure 11 shows another variant of a mobile, cuboid-shaped battery device with a wider side compared to the vertical orientation. In this alternative arrangement, the cooling fins 22 of the heat sink 21 run parallel to the lateral edge of the device. The outputs, again shown here without the switch plate 17, are also arranged somewhat differently than in the previous example according to Figure 10, which illustrates the arbitrary nature of their arrangement. It is understood that the number of sockets or outputs can also vary here. In an alternative embodiment of the battery device, the fan 23 can be omitted, particularly for noise-sensitive applications. However, it is advantageous to have a low-power fan 23, which remains switched off when not needed.

[0024] A key feature of the inventive battery device is that it opens up the application range of high-voltage batteries for the mobile energy supply sector. High-voltage systems (HV) are defined as systems that operate with alternating current voltages above 30 V up to 1 kV or with direct current voltages above 60 V up to 1.5 kV. The term "high voltage" as used here originates from automotive engineering and is called "high" because such voltages are dangerous to humans. A battery is a direct current source, and the designation "high-voltage battery" is therefore based on its direct current voltage (referring to the nominal voltage). A significant advantage of the high voltage U of a high-voltage battery is that the current I is comparatively low for a given power P (P = U ■ I).For applications, this means that the same performance is easier to achieve in a high-voltage system than with the difficult-to-handle high currents in a low-voltage system. For example, at high voltages and correspondingly low currents, thinner cables with a smaller conductor cross-sectional area can be used. This allows for savings in materials and cooling, and enables significant weight reductions. So far, however, high-voltage batteries are primarily used in electric vehicles or as stationary storage systems for solar applications. One reason for this limited application is the technological challenge of meeting the safety requirements resulting from the higher voltage and manufacturing the necessary components in a compact design and at a relatively low weight. to provide a suitable weight so as not to compromise the device's portability. Advantageously, the total weight of the device according to the invention should be less than 100 kg, so that it can be lifted by a single person when necessary and easily carried by two people over longer distances.

[0025] In light of the previous use of high-voltage batteries, the inventive mobile battery device breaks entirely new ground by providing, in a preferred variant, a battery pack with a high-voltage nominal voltage, i.e., with a nominal voltage of more than 60 V, for mobile applications, with the device being portable by hand, sometimes for use outdoors.

[0026] Figure 12 shows the circuit diagram of the electronics according to a preferred embodiment of the mobile battery device. The abbreviations mean the following: • HMI = Human Machine Interface • CAN = Controller Area Network • Iso-Monitor = Insulation monitoring device (= insulation monitor) • BMS = Battery Management System (= battery management system) • Bidirectional Inverter = Bidirectional Inverter • Bidirectional DC / DC Converter • BAT+ = Positive Battery Terminal (= battery plus pole) • BAT- = Negative Battery Terminal (= battery negative pole) • AI = Analog Input (= analog input) • HV = High Voltage (= high voltage) • C[...] = Cell (accumulator cell), [...] = identification numbers of the accumulator cells • DI, DO = Digital Input, Digital Output (= digital input interface, digital output interface) The power electronics include a BMS master, namely a main control unit that coordinates communication with the four BMS slaves and manages all important functions of the BMS. The BMS master can then The BMS Master makes decisions to optimize battery performance and safety by controlling charging and discharging processes and issuing warnings when problems occur. This ensures that the battery operates within specified limits. To achieve this, the BMS Master collects and analyzes data provided by the BMS Slaves, small, autonomous monitoring units, such as voltage, current, temperature, and the condition of each battery cell (24). The BMS Slaves are located near the battery cells (24). They can also make local decisions to ensure the safety of the cells (24), such as disconnecting cells (24) if their voltage falls outside the permissible range. The master-slave system enables efficient and precise operation of the battery system.Furthermore, redundant monitoring functions are provided by having multiple monitoring units collect and analyze the same information to increase system reliability and safety. The HMI (Human-Machine Interface) provides the user with easy access to battery status information and control of charging and discharging processes. The HMI displays important information such as the current battery status, remaining battery capacity, charging and discharging power, and temperature. The user can also adjust parameters such as the maximum charging voltage, maximum discharging voltage, and maximum charging or discharging power of the battery.

[0027] Furthermore, for the power electronics in the battery device according to the invention, two modules 25, i.e., component-equipped printed circuit boards, are preferably used for the power converters. The two modules are then programmed such that one module operates as a bidirectional DC-DC converter and the other as a bidirectional three-phase inverter, which are integrated into a single unit. They work together to enable the bidirectional conversion between three-phase AC and DC. These integrated 1 The design offers a compact form factor. The inverter preferably comprises a bidirectional three-phase full bridge.

[0028] In this context, a transformerless version of the inverter proves to be This is advantageous because it saves weight. To ensure that a desired output voltage of, for example, 400 V is provided for power-intensive applications, the comparatively lower battery voltage, which is, for example, 200 V, must be stepped up by the DC-DC converter to an intermediate DC voltage. The inverter then converts this to the corresponding AC output voltage. The voltage stepped up by the DC-DC converter must be higher than the required output voltage of 400 V, so that the DC-DC converter can preferably step up the voltage to at least 600 V or at least 650 V.

[0029] Thanks to its safe and efficient design, the battery device according to the invention achieves an unprecedentedly high ratio of the gross capacity of the battery or battery pack (i.e., the amount of electrical charge that the battery of the device can store) to the residual weight of the mobile battery device, i.e., to the total weight of the mobile battery device minus the battery weight, thus minus the weight of the battery pack, and in the case of multiple battery packs, minus the weight of all battery packs. This ratio of battery capacity to the residual weight of the mobile battery device according to the invention achieves energy densities of at least 0.1 kWh / kg. Preferably, this ratio achieves energy densities of at least one of the following values: {0.125 kWh / kg, 0.15 kWh / kg, 0.175 kWh / kg, 0.2 kWh / kg, 0.225 kWh / kg, 0.25 kWh / kg}. With a total weight of the battery device according to the invention of approximately 80 kg, a battery pack weighing approximately...40 kg on a residual weight of the device of only approximately 40 kg. With a battery capacity of 8 kWh, this corresponds to an energy density of the mobile battery device relative to the residual weight, i.e., the ratio of battery capacity : residual weight, of 8 kWh : 40 kg = 0.2.

[0030] Furthermore, the battery device according to the invention preferably also fulfills the following condition with regard to energy density: The ratio of the battery capacity to the residual weight of the mobile battery device, i.e., to the total weight of the mobile battery device, less the weight of the battery pack and, in the case of several battery packs, less the weight of all battery packs and further less the weight of the The housing 1, without a heat sink 21, achieves energy densities of at least 0.2 kWh / kg. This additional condition expresses how low the weight of the internal components of the mobile battery device is, regardless of the battery weight, given the available energy capacity of the battery. With a total weight of the mobile battery device according to the invention of approximately 80 kg and a housing 1 without a heat sink 21 of approximately 15 kg, a battery weighing 40 kg encounters a residual weight of the device of only 25 kg (= 80 kg - 15 kg - 40 kg) and achieves an energy density of 0.3 kWh / kg with a battery capacity of 8 kWh. According to the invention, the device achieves an energy density based on the residual weight less the weight of the device housing 1 of at least 0.2 kWh / kg, and preferably one of the following minimum values ​​{0.225 kWh / kg, 0.25 kWh / kg, 0.275 kWh / kg, 0.3 kWh / kg, 0.325 kWh / kg}.This device is therefore available as an extremely lightweight, highly efficient mobile energy source for three-phase consumers and enables its use even in remote locations.

[0031] In particular, an optimized ratio is achieved by using a high-voltage battery. Preferably, the nominal voltage of the battery pack used in the mobile battery device is then more than 60 V, and more preferably equal to or greater than 100 V. Preferred embodiments of the device according to the invention use a battery pack with a nominal voltage of equal to or greater than 150 V, or more preferably equal to or greater than 200 V. This also applies when using multiple battery packs in the device.

[0032] Figure 13 shows the interior of the mobile battery device. On the side facing away from the front 15, or rear, the heat sink 21 with its internal cooling plate can be seen. The power modules 25 are connected to this heat sink via thermal bridges. The fans 23 circulate air inside the housing 1 to enhance the cooling effect as needed. Also shown is area 26 containing the BMS, insulation monitor, and battery electronics on separate circuit boards, as well as the area with safety elements 27. For redundancy, two different current sensors are preferred in this battery system, for example, a Hall sensor and a shunt sensor. Two relays and a fuse are advantageously used as safety components. Protection is built in. The number of circuit boards depends on the design of the power electronics. It would also be possible to accommodate everything on a single circuit board. Also shown is the advantageous arrangement of one or more common-mode filters 29 for reducing interference and improving electromagnetic compatibility (EMC), as well as one or more contactors 28. Furthermore, Figure 13 shows that the housing 1 is equipped with an eyelet 30 on each side of the device. Such eyelets 30 are optional if the device is to be transportable by crane. The device housing 1 is reinforced here by cross braces 40 and a box frame 41.

[0033] Figure 14 shows an interior view of a mobile battery device (without wheels) mounted on support rails, looking towards the other side of the device compared to the view in Figure 13. This clearly shows, among other things, the area 34 with two common-mode filters 29 (one single-stage and one two-stage) and contactors 28. A single common-mode filter 29 would also be possible. This reduces electromagnetic interference (EMI) and noise. A common-mode filter eliminates common-mode interference by providing high resistance to signals that are identical on both conductors (common mode). The power modules 25 visible in front of the heat sink 21 are described below. Advantageously, the device housing 1 is prepared with nuts 39 in corresponding holes in the housing 1 for attaching or screwing in a suitable lifting device, such as an eyelet 30.The housing 1 is robustly constructed to meet the requirements of a vibration test. For the embodiment of the device shown here, the struts 40 and frame reinforcements 41 create a particularly robust housing 1, especially with regard to potential crane transport of the device. Also circled in Figure 14 are the battery electronics 31, the power electronics 32 with three-phase inverter and DC-DC converter, the battery pack 33, and electromechanical components 34, including contactor 29.

[0034] Figure 15 illustrates how the power modules 25 are attached to the circuit boards using set screws, so that they are connected to the mounted state. Connect the rear plate of the heat sink 21 of the device, directly and / or indirectly via thermal bridges. Thermal bridges can be formed, for example, by thermally conductive gap-filling material, which hardens irreversibly at room temperature or at a higher temperature (with hot air) in a curtain. This arrangement of the power modules 25 for the power converters on the rear of the mobile battery device allows for space-saving accommodation of the internal components and a compact arrangement of the heat sink 21. The power modules 25 can have other dimensions and arrangements, which also applies to the heat sink 21.

[0035] Figure 16 shows the circuit boards of the modules 25 with their electronic components and connections. These modules are bidirectional AFE modules (AFE stands for Active Front End). Generally, an AFE is used to improve power factor correction (PFC) while simultaneously reducing harmonics and disturbances in the power supply. It is a power electronic circuit that enables bidirectional energy flow control and efficient conversion between different voltage and current levels. The modules can operate as boost, buck, or PFC converters (boost = voltage increase, buck = voltage reduction, PFC = power factor correction).The thick cables 35 at one end of the lower circuit board are the connection cables to the battery pack. At the opposite end of the other circuit board are the cables 36, which connect to the common-mode filter 29. Also visible is a so-called daisy chain 37, i.e., a serial connection between the two modules for transmitting data and control signals or for communication. The two cables 38 located nearby are jumper cables between the modules with a discharge resistor.

[0036] The following specifications with preferred ranges of their values ​​for embodiments of the mobile battery device according to the invention are given as an example. Furthermore, the mobile battery device according to the invention is characterized by the following advantageous features, individually or in any combination: • A continuous discharge power of 8-15 kVA; • The ability to charge the battery with direct current; • A GPS module on the device; • Charging option via a PV kit attached to the device; • Possibility of parallel charging and discharging (grid parallel mode); • Possibility of connecting two mobile battery devices in parallel to extend the capacity provided by the individual batteries; • Manual portability of the device; • Crane transportability of the device.

[0037] In particular, a preferred embodiment of the mobile battery device according to the invention has one or more or any combination of the features listed below: 1 Standard charging at 0.2 C, 25°C / Charging at 0.2 C, 25°C. 2 Standard charging at 0.2°C, 25°C / Discharging at 0.5°C, 25°C. 3 Up to 90% SoC 4 For 10 seconds, cos(cp) 0.7...1 5 cos(cp) 0.7...1 6 Other plug types available on request 7 At nominal power 8 Without wheels, cables and attachments 9 Without wheels and cables 10 Integrated according to the IEC 61508 standard

[0038] Figures 17a-c show an embodiment of the mobile battery device with support rails located at the bottom of the device. Figures 17d-g, on the other hand, show the mobile battery device with wheels and leveling feet. In both embodiments of the device, optional eyelets 30 are screwed into the housing 1 at the top of its broad sides for possible crane transport of the device. These can be removed if not required. The housing 1 of the device is advantageously reinforced with a box frame 41. Internally, it can be reinforced with struts 40 to further increase its stability. Figures 17a, 17b, 17d-f show the dimensions H, B', B", L', L" and L'". B' denotes the width of the device including support rails and is advantageously between 300 and 450 mm, while B" denotes the width of the device including its wheels 8, 9 and is advantageously between 500 mm and 650 mm.L' denotes the length of the device without lifting handles 4, 5, L" the length including lifting handles 4, 5, and L'" the length including wheels 8, 9 and support feet 12, 13. Advantageous dimensions for L' are between 650 mm and 850 mm, for L" between 850 mm and 1050 mm, and for L'" between 750 mm and 950 mm. Figure 17d also shows: a display 42 for the user interface (e.g., a touch display for selecting functions of the device), an on / off switch 43, an emergency stop switch 44, a three-phase output or three-phase socket 19, a single-phase socket 45 (one of three such sockets shown here), a CAN output 46, and a 24 V output 47. which, depending on requirements, can also be designed for a different voltage, an output 48 for PV charging or DC charging, a charging cable socket 49, and a pressure relief or safety valve 50, which encloses an elastic diaphragm and opens to release pressure when it exceeds a critical value, and closes again when the pressure has dropped to a safe level. In Figure 17e, a GPS antenna 51 is also shown above the uppermost single-phase socket 46. It is understood that the aforementioned outputs for consumers, switches, and communication interfaces on the device according to the invention are independent of whether a specific device has wheels 8, 9 and support feet 12, 13 or support rails, eyelets 30 or no eyelets 30, or whether the housing is reinforced with a box frame 41 as shown, etc.

[0039] The device according to the invention enables a battery or battery pack to be transformed into a mobile power supply unit for demanding indoor and outdoor applications in a compact space and with minimal weight. The efficiency of a mobile battery device's residual weight is demonstrated when a high-capacity battery or battery pack can be integrated into a mobile power supply unit for demanding applications with minimal space requirements and weight increase. For this purpose, the battery device according to the invention makes it particularly suitable for high-voltage batteries, which are securely and compactly integrated within it with minimal weight. Due to its low weight and small volume, the battery device according to the invention can be moved manually to virtually any location, thus opening up new areas of application that previously made the use of industrial consumer devices considerably more difficult, if not impossible.For example, areas of application include construction sites, events of all kinds, campsites, open spaces and forests, mountainous regions, and especially remote locations or those difficult to access, for example, due to disasters. The battery-powered device is also suitable as an emergency power generator, for instance, during periods of low energy availability in winter or when the power grid is overloaded, to ensure an uninterrupted power supply wherever needed.

[0040] The object of the invention is further achieved with the methods described below. advantageous embodiments of the mobile battery device according to the invention, namely a mobile battery device with the features according to one of claims 1 to 18, wherein the mobile battery device further comprises a feature or any combination of features according to the following paragraphs, namely...

[0041] ...where the energy density of the battery device, based on its residual weight, which corresponds to the total weight of the battery device less the weight of the battery pack or, in the case of multiple battery packs, the weight of all battery packs, is thus the gross capacity of the battery pack or, in the case of multiple battery packs, their total gross capacity divided by the residual weight, is at least one of the values ​​{0.125 kWh / kg, 0.15 kWh / kg, 0.175 kWh / kg, 0.2 kWh / kg, 0.225 kWh / kg, 0.25 kWh / kg}.

[0042] ...where the gross capacity of the battery pack, or in the case of multiple battery packs, their total gross capacity divided by the weight calculated as the residual weight less the weight of the housing 1 without heat sink 21, is at least one of the values ​​{0.15 kWh / kg, 0.175 kWh / kg, 0.225 kWh / kg, 0.25 kWh / kg, 0.275 kWh / kg, 0.3 kWh / kg, 0.325 kWh / kg}.

[0043] ...where the gross capacity of the battery pack, or in the case of multiple battery packs, their total gross capacity divided by the weight of one heat sink 21, or in the case of multiple heat sinks 21, of all heat sinks 21, is at least one of the values ​​{0.75 kWh / kg, 1.25 kWh / kg, 1.5 kWh / kg, 1.75 kWh / kg, 2 kWh / kg, 2.25 kWh / kg, 2.5 kWh / kg}.

[0044] ...whereby the weight fraction of one heat sink 21 or, in the case of several heat sinks 21, of all heat sinks 21, to the total weight of the battery device is not more than one of the values ​​{10%, 9%, 8%, 7%, 6%, 5%}.

[0045] ...whereby one or, in the case of several, heat sinks 21 have a total thermal resistance (K / W) which depends on the The weight of the heat sink 21 ITIK in kg, or in the case of several heat sinks 21, of their total weight mK in kg is less than -0.02 K / (W-kg) ■ ITIK + 0.3 K / W.

[0046] ...whereby the battery device is cooled exclusively by air cooling.

[0047] ...whereby, starting from a power loss of one or, in the case of several battery packs, of the battery packs as a whole, this outgoing power loss is reduced by creating a variable intermediate circuit voltage and / or by reducing an output voltage of the battery pack(s) by at least one of the values ​​{10%, 12.5%, 15%, 17.5%, 20%} compared to the outgoing power loss.

[0048] ...where the gross capacity of the battery pack, or in the case of multiple battery packs, their total gross capacity divided by the weight of one common-mode filter 29, or in the case of multiple common-mode filters 29, of all common-mode filters 29, is at least one of the values ​​{1.75 kWh / kg, 2 kWh / kg, 2.25 kWh / kg, 2.5 kWh / kg, 2.75 kWh / kg, 3.25 kWh / kg, 3.5 kWh / kg, 3.75 kWh / kg, 4 kWh / kg, 4.25 kWh / kg, 4.5 kWh / kg, 4.75 kWh / kg, 5 kWh / kg}.

[0049] ...whereby the battery device contains at least one single-stage and one two-stage common-mode filter 29.

[0050] ...whereby the battery device includes one or more fans 23 for circulating air cooling in the housing 1, with such a maximum power of the one fan 23 or, in the case of several fans 23, with such a maximum total power that the gross capacity of the battery pack, or, in the case of several battery packs, their total gross capacity divided by the maximum power of the one fan 23, or, in the case of several fans 23, their total maximum power, is at least one of the values ​​{1500 h, 2000 h, 2500 h, 3000 h, 3500 h, 4000 h, 4500 h}.

[0051] ...where the power of one fan is 23, or in the case of multiple fans, 23... The total power consumption of the multiple fans 23 must not exceed one of the values ​​{1 W, 2 W, 3 W, 4W, 5W, 6W, 7W, 8W, 9W, 10W}.

[0052] ...whereby the housing 1 is closed, irrespective of openings for outlets for consumers, switches and communication interfaces, except for openings for one-way outlets and / or openings for cooling with ambient air, wherein the cooling openings are dimensioned such that a solid foreign body whose diameter is at least one of the values ​​{0.5 mm, 0.75 mm, 1.25 mm, 1.5 mm, 1.75 mm, 2 mm, 2.25 mm, 2.5 mm} cannot pass through them.

[0053] ...where the total weight of the battery device is less than one of the following values: {120 kg, 115 kg, 110 kg, 105 kg, 100 kg, 95 kg, 90 kg, 85 kg, 80 kg}.

[0054] ...where the nominal voltage of the battery pack, or in the case of multiple battery packs, of each battery pack is at least one of the following values: {60 V, 80 V, 100 V, 125 V, 150 V, 175 V, 200 V}.

[0055] ...where the gross capacity of the battery pack, or in the case of multiple battery packs, the total capacity of the battery packs is at least one of the following values: {6 kWh, 6.5 kWh, 7 kWh, 7.5 kWh, 8 kWh, 8.5 kWh, 9 kWh}.

[0056] ...wherein the gross capacity of the battery pack or, in the case of several battery packs, the battery packs as a whole is at most one of the values ​​{10 kWh, 10.5 kWh, 11 kWh, 11.5 kWh, 12 kWh, 12.5 kWh, 13 kWh, 13.5 kWh, 14 kWh, 14.5 kWh, 15 kWh, 16 kWh, 17 kWh, 18 kWh, 19 kWh, 20 kWh}.

[0057] ...where the battery device includes a bidirectional DC-DC converter.

[0058] ...where the battery device includes a bidirectional DC-DC converter, and the nominal voltage of the battery pack, or in the case of multiple battery packs, of each battery pack, is at most one of the values ​​{200 V, 250 V, 300 V, 350 V, 400 V, 450 V, 500 V, 550 V, 600 V}.

[0059] ...whereby the three-phase inverter comprises a bidirectional three-phase full bridge.

[0060] ...where the thickness of the plates that make up the housing 1 is at least one of the values ​​{1 mm, 1.25 mm, 1.5 mm, 1.75 mm, 2 mm}.

[0061] ...whereby the housing 1 is essentially cuboid or purely cuboid in shape, with a length of housing 1 of at most one of the values ​​{1200 mm, 1150 mm, 1100 mm, 1050 mm, 1000 mm, 950 mm}, a width of housing 1 of at most one of the values ​​{700 mm, 650 mm, 600 mm, 550 mm, 500 mm, 450 mm} and a height of housing 1 of at most one of the values ​​{900 mm, 850 mm, 800 mm, 750 mm, 700 mm, 650 mm}.

[0062] ...where the housing 1 is made of metal sheet or plastic.

[0063] ...where the housing 1 is made of sheet steel and / or sheet aluminum.

[0064] ...whereby housing 1 is designed to be dustproof.

[0065] ...where the housing 1 is reinforced with struts.

[0066] ...whereby the case 1 is reinforced with struts which frame a contour of the case 1.

[0067] ...where the heat sink 21 is designed as a profile.

[0068] ...whereby the heat sink forms 21 cooling fins 22 spaced apart from each other.

[0069] ...whereby the heat sink forms 21 spaced-apart cooling fins 22 of a corrugated structure.

[0070] ...where the weight of the heat sink 21 is less than one of the values ​​{10 kg, 9 kg, 8 kg, 7 kg, 6 kg, 5 kg}.

[0071] It is understood that where a feature mentions "multiple" units, components, etc., two or more such units, components, etc. are meant.

[0072] In particular, an advantageous embodiment of the mobile battery device achieves that it provides a high gross battery capacity at a low device weight, whereby • the device provides three-phase current for three-phase machines and systems; • its housing withstands mechanical stress due to impact, such as can occur during outdoor use, thus enabling reliable function and safe use of the device both outdoors and indoors; • the electromagnetic compatibility (EMC) of the battery device is sufficient to make the device suitable for both outdoor and indoor use; • the device is portable by hand.

[0073] legend 1 case 2 Base plate of the housing 1 3 handcarts 4 Lifting handle 5 Lifting handle 6 Lifting handle with plate 14 7 wheel axle 8 wheel wheel Corner area Corner area Support leg Support leg Plate for tilting and pulling the battery device Front side of the battery device Guide rail Switch plate Handle Three-phase AC output (three-phase output) Cooling surface heat sink Cooling fins Fan for recirculating air cooling Accumulator cells Power module Area with BMS Area with safety elements Schütz Common mode filter Eyelets for crane transport Battery electronics Power electronics with three-phase inverter and DC / DC converter Battery pack Electromechanical components, including contactor 29 Connection cable to battery pack 33 Cable 36, which connects to the common-mode filter 29 Daisy Chain Jumper cables between the modules 25 Mother crossbar Box frame Display On / Off switch Emergency stop switch, single-phase socket CAN output 24V output Output for PV charging or DC charging Charging cable socket Overpressure or safety valve GPS antenna

Claims

Claims: Battery device for making three-phase alternating current available regardless of location, comprising a housing (1) with a three-phase alternating current output (19), wherein the housing (1) contains one or more battery packs, at least one bidirectional three-phase inverter and one or more common-mode filters (29), and the housing (1) includes one or more heat sinks (21) with a heat-dissipating surface for dissipating waste heat to the ambient air, and wherein the energy density of the battery device, based on its residual weight, which corresponds to the total weight of the battery device less the weight of the battery pack or, in the case of several battery packs, less the weight of all battery packs, is thus the gross capacity of the battery pack or, in the case of several battery packs, their total gross capacity divided by the residual weight, is at least 0.1 kWh / kg.Battery device according to claim 1, wherein the gross capacity of the battery pack, or in the case of multiple battery packs, their total gross capacity divided by the weight calculated as the residual weight less the weight of the housing (1) without the heat sink (21), is at least 0.2 kWh / kg. Battery device according to any one of the preceding claims, wherein the gross capacity of the battery pack, or in the case of multiple battery packs, their total gross capacity divided by the weight of one heat sink (21), or in the case of multiple heat sinks (21), of all heat sinks (21), is at least 1 kWh / kg. Battery device according to any one of the preceding claims, wherein the gross capacity of the battery pack, or in the case of multiple battery packs, their total gross capacity divided by the weight of one common-mode filter (29), or in the case of multiple heat sinks (21), is at least 1 kWh / kg. The power consumption of several common-mode filters (29) of all common-mode filters (29) is at least 3 kWh / kg. A battery device according to one of the preceding claims, wherein the battery device includes one or more fans (23) for forced-air cooling in the housing (1), with such a maximum power of one fan (23) or, in the case of several fans (23), with such a maximum combined power of the fans (23) that the gross capacity of the battery pack, or, in the case of several battery packs, their total gross capacity divided by the maximum power of one fan (23), or, in the case of several fans (23), their total maximum power, is at least 1000 h.Battery device according to any one of the preceding claims, wherein the housing (1) is closed, except for openings for outputs for consumers, switches, and communication interfaces, except for openings for one-way outlets and / or openings for cooling with ambient air, wherein the cooling openings are dimensioned such that a solid foreign body with a diameter of at least 1 mm cannot pass through them. Battery device according to any one of the preceding claims, wherein the battery device includes a bidirectional DC-DC converter, and the bidirectional three-phase inverter and the bidirectional DC-DC converter are designed as a single unit. Battery device according to any one of the preceding claims, wherein the... Three-phase inverter designed without a transformer. Battery device according to one of the preceding claims, wherein the Nominal voltage of the battery pack, or in the case of multiple battery packs, of each battery pack exceeding 60 V. Battery device according to one of the preceding claims, wherein the housing (1) is substantially cuboid or purely cuboid, with a A battery device with a maximum length of 900 mm, a maximum width of 400 mm, and a maximum height of 600 mm, according to any of the preceding claims, wherein the housing (1) has at least one handle (4, 5, 6, 18) by which it can be manually moved. A battery device according to any of the preceding claims, wherein the total weight of the battery device is less than 100 kg. A battery device according to any of the preceding claims, wherein the housing (1) has at least one handle (4, 5, 6, 18), and the battery device is designed as a handcart (3) with at least one wheel (8, 9) on the housing (1) for manually rolling the battery device by means of the at least one handle (4, 5, 6, 18).Battery device according to claim 13, wherein the handcart (3) has support feet (12, 13) on a side of the housing (1) opposite the single wheel or wheels (8, 9), such that the handcart (7) can be tilted about the axis (16) of the wheel(s) (8, 9) and can be placed on a level surface in a horizontal position of the housing (1) by means of the support feet (12, 13), and that the handcart (3) has a lifting handle (6, 18) for tilting and rolling it. Battery device according to any one of claims 11 to 14, wherein the housing (1) includes a base plate (2) and the base plate (2) is vertically spaced at least 10 cm from the base plate when the battery device is placed on a level surface.Battery device according to one of claims 13 to 15, wherein the housing (1 ) includes a base plate (2) and the hand trolley (3) has a lifting handle (6) extendable along the base plate (2) of the housing (1 ) with plate (14) and end-side handle attached thereto, wherein the plate (14) is extendable in a normal direction to an end face (15) of the hand trolley (3) or the hand trolley (3). a handle (18) that folds out in the normal direction to the front face (15) of the handcart (3). Battery device according to one of claims 13 to 16, wherein the handcart (3) has a fixed or foldable lifting handle (4, 5) at each of two opposing upper corner regions of the housing (1). Battery device according to one of the preceding claims, wherein the housing (1) contains at least two struts (35) that each extend along a longitudinal edge of a top plate of the housing (1).

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