ASSEMBLY OF IDENTICAL CELL MODULES FOR CELLULAR BATTERIES

Abstract

A method enables the assembly of a module suitable for use in a cellular battery, comprising a rigid casing in which are housed at least two identical electrical energy storage cells, having a non-cubic parallelepiped shape, each with first and second pairs of opposite lateral faces, and each comprising two first sides and two second sides having different first and second dimensions, respectively. This method includes a step (10-20) in which all the first sides are positioned according to the same spatial orientation, chosen from perpendicular first and second spatial orientations, depending on whether the rigid casing has a third dimension, along a cell installation direction corresponding to the first or second dimension, and then the rigid casing is defined around the positioned cells. Figure 5

Description

Title of the invention: ASSEMBLY OF IDENTICAL CELL MODULES FOR CELLULAR BATTERIES Technical field of the invention

[0001] The invention relates to cellular batteries comprising modules of at least two electrical energy storage cells, and more specifically the assembly of such modules. State of the art

[0002] In many fields, such as for example that of vehicles (possibly of the automobile type), cellular batteries are used, each comprising at least one module having at least two electrical energy storage cells.

[0003] Typically, a module comprises a rigid casing inside which identical (electrical energy storage) cells with the same orientation are installed. This rigid casing is mainly made up of plates that are welded together around the cells after the latter have been positioned.

[0004] By varying the number of cells in the modules, the modules can have different lengths and / or widths. However, the height of the modules remains essentially the same since they contain identical cells with the same orientation. This poses a problem when using battery cells of different heights in different types of vehicles. While it is possible to assemble the modules with different spatial orientations to obtain battery cells of varying heights, this can complicate the internal architecture of some battery cells and / or create empty areas within certain batteries because the internal space cannot be optimally utilized, thus reducing the electrical energy storage capacity.

[0005] The invention therefore aims in particular to improve the situation. Presentation of the invention

[0006] In particular, it proposes for this purpose an assembly method for assembling a module suitable for forming part of a cellular battery and comprising a rigid casing in which are housed at least two identical electrical energy storage cells, having a non-cubic parallelepiped shape, and each with i) first and second pairs of opposite lateral faces and each comprising two first sides and two second sides having respectively of different first and second dimensions, and ii) two end faces opposite and perpendicular to the lateral faces.

[0007] This assembly method is characterized by the fact that it includes a step in which all the first sides are positioned according to the same spatial orientation, chosen from among first and second perpendicular spatial orientations depending on whether the rigid envelope has a third dimension, following a cell installation direction, which corresponds to the first dimension or the second dimension, and then this rigid envelope is defined around the positioned cells.

[0008] Thanks to the invention, it is now possible to vary not only the "length" and "width" of the modules, but also the "height" (direction concerned by the third dimension) of these modules, which allows the design of cellular batteries of different heights adapted to vehicles of different types, while these modules each include identical cells.

[0009] The assembly method according to the invention may include other features which may be taken separately or in combination, and in particular:

[0010] - in its stage, when the third dimension is intended to be parallel to a vertical installation direction, the first and second spatial orientations may be intended to be respectively parallel to this vertical installation direction, and to a horizontal direction perpendicular to the vertical installation direction;

[0011] - in its step, the cells can be positioned one behind the other following the minus one row perpendicular to the direction of installation;

[0012] - in its step, when each cell has a first end face equipped with with two connection terminals and a second end face without a connection terminal, all cells can be positioned with their first end faces in the same plane perpendicular to the direction of installation;

[0013] - alternatively, in its step, when each cell has a first end face equipped with two connection terminals and a second end face without a connection terminal, all cells belonging to two adjacent and parallel rows can be positioned with their second or first end faces placed opposite each other and parallel to the direction of installation.

[0014] The invention also proposes a computer program product comprising a set of instructions which, when executed by processing means, is suitable for implementing an assembly method of the type presented above for assembling a module suitable for being part of a cellular battery and comprising a rigid casing in which are housed at least two identical electrical energy storage cells having a non-cubic parallelepiped shape.

[0015] The invention also proposes a control device intended to be part of an assembly installation suitable for assembling a module suitable for being part of a cellular battery and comprising a rigid casing in which are housed at least two identical electrical energy storage cells, having a non-cubic parallelepiped shape, and each with i) first and second pairs of opposite lateral faces and each comprising two first sides and two second sides having respectively different first and second dimensions, and ii) two end faces opposite and perpendicular to the lateral faces.

[0016] This control device is characterized in that it comprises at least one processor and at least one memory arranged to perform the operations of triggering:

[0017] - a positioning, by the assembly installation, of all the first sides according to a single spatial orientation, chosen from first and second perpendicular spatial orientations depending on whether the rigid envelope has a third dimension, following a cell installation direction corresponding to the first or second dimension, then

[0018] - a definition, by the assembly installation, of the rigid casing around the cells positioned.

[0019] The invention also proposes an assembly installation, on the one hand, intended to allow the assembly of modules suitable for forming part of cellular battery(ies) and comprising a rigid casing in which are housed at least two identical electrical energy storage cells, having a non-cubic parallelepiped shape, and each with i) first and second pairs of opposite lateral faces and each comprising two first sides and two second sides having respectively different first and second dimensions, and ii) two end faces opposite and perpendicular to the lateral faces, and, on the other hand, comprising a) at least one robotic arm suitable for successively grasping cells placed in a storage location and for positioning all the first sides according to the same spatial orientation, chosen from among first and second spatial orientations perpendicular depending on whether the rigid casing has a third dimension,following a cell installation direction, corresponding to the first or second dimension, then defining the rigid envelope around the positioned cells, and b) a control device of the type presented above and suitable for controlling this (each) robotic arm. Brief description of the figures

[0020] Other features and advantages of the invention will become apparent from an examination of the detailed description below, and the accompanying drawings, in which:

[0021] [Fig-1] illustrates schematically and functionally, in a perspective view Above, part of an example of a cellular battery comprising modules assembled according to the invention,

[0022] [Fig.2] schematically and functionally illustrates a first example of a realization assembly of a cellular battery module, according to the invention,

[0023] [Fig.3] schematically and functionally illustrates a second example of a assembly of a cellular battery module, according to the invention,

[0024] [Fig.4] schematically and functionally illustrates an example of the realization of a a computer comprising a control device according to the invention and intended to equip an assembly installation according to the invention, and

[0025] [Fig.5] schematically illustrates an example of an algorithm implementing an assembly method according to the invention. Detailed description of the invention

[0026] The invention aims in particular to propose an assembly method intended to allow the assembly of MC modules suitable for forming part of BC cellular battery(ies) and comprising at least two identical CE electrical energy storage cells, and a DC control device intended to allow the control of this assembly within an assembly installation.

[0027] In what follows, it is considered, by way of non-limiting example, that BC cellular batteries are intended for use in motor vehicles, such as cars. However, the invention is not limited to this application. Indeed, BC cellular batteries comprising MC modules assembled according to the invention can be part of any system. Thus, they can be part of vehicles (land, sea (or river), or air), electronic devices (possibly household appliances), mobile equipment (including those that perform a lifting function), installations (possibly industrial), and buildings, for example.

[0028] In Figures 1 to 3, direction X is intended to be parallel to the longitudinal direction of a vehicle, which is substantially parallel to the lateral (or longitudinal) sides containing the side doors; direction Y is perpendicular to direction X and is intended to be parallel to the transverse direction of the vehicle (which is perpendicular to its longitudinal direction); and direction Z is perpendicular to directions X and Y and is intended to be parallel to the vertical direction of the vehicle (which is perpendicular to its longitudinal and transverse directions). However, directions X, Y, and Z might not be parallel to the longitudinal, transverse, and vertical directions of a vehicle, respectively.

[0029] A schematic representation in [Fig.1] shows part of an example of a BC cellular battery comprising MC modules assembled by means of the implementation of the assembly process according to the invention.

[0030] It should be noted that in the example illustrated, but not limited to, in [Fig. 1], the BC cellular battery comprises at least three MC modules of at least two CE cells. However, the number of MC modules in a BC cellular battery can take any value greater than or equal to two.

[0031] Each MC module can be equipped with at least one first IEC electronic board responsible for controlling and monitoring the operation of the CE cells it comprises, and in particular for determining operating parameters such as internal current and internal temperature. In the example illustrated, but not limited to, in [Fig. 1], the first IEC electronic boards are installed on the "top" face of the MC modules, but this is not mandatory. Furthermore, and as illustrated at least partially in [Fig. 1], each MC module can have two opposite ends, each equipped with two first BOC1 connection terminals.

[0032] The first two BOC1 connection terminals of each end of an MC module are respectively connected to corresponding first BOC1 connection terminals of neighboring MC modules via inter-module conductive lines LC1. In other words, the first first BOC1 connection terminal of a first end of an nth MC module is connected to the second first BOC1 connection terminal of a first end of an (nl)th MC module, and the second first BOC1 connection terminal of this first end of the nth MC module is connected to the first first BOC1 connection terminal of the first end of the (n+l)th MC module.Similarly, the first BOC1 connection terminal of a second end of an nth MC module is connected to the second BOC1 connection terminal of a second end of an (nl)th MC module, and the second BOC1 connection terminal of this second end of the nth MC module is connected to the first BOC1 connection terminal of the second end of the (n+l)th MC module.

[0033] The MC modules are therefore mounted in series here and the intermodule conductive lines LC1, which interconnect them, define a current line which starts at the level of the MC module located further upstream and extends to the MC module located further downstream and then from the latter to the MC module located further upstream.

[0034] As illustrated in the examples in Figures 2 and 3, once assembled according to the invention, an MC module comprises a rigid enclosure ER in which are housed at least two identical CE electrical energy storage cells having a non-cubic parallelepiped shape. Each rigid enclosure ER has dimensions that characterize it, and in particular a third dimension d3 which is defined according to the installation direction of the CE cells.

[0035] It should be noted that in the example illustrated, but not limited to, in Figures 1 to 3 the The third dimension d3 concerns the extension of the rigid shell ER along the Z direction, which, in this case, is intended to be parallel to the vertical direction of a vehicle. However, the third dimension d3 could also concern the extension of the rigid shell ER along the X or Y direction.

[0036] It should also be noted that in the example illustrated, but not limited to, in Figures 2 and 3, only two CE cells are represented, placed side by side in two rows parallel to the Y direction. However, in an MC module, CE cells can be placed one behind the other within row(s), here parallel to the Y direction. Furthermore, the number of CE cells in an MC module can take any value greater than or equal to two, and the number of rows of CE cell(s) in an MC module can take any value greater than or equal to one.

[0037] As illustrated in Figures 2 and 3, each cell CE has a first pair of lateral faces FL1 (k = 1) opposite each other, and a second pair of lateral faces FL2 (k = 2) opposite each other. Furthermore, each lateral face FLk is rectangular (not square) and therefore comprises two first sides cl having a first dimension dl, and two second sides c2 having a second dimension d2, different from the first dimension dl.

[0038] Each CE cell also comprises two end faces FEj (j = 1 or 2) opposite and perpendicular to the lateral faces FLk. In addition, here, a first end face FE1 (j = 1) is provided with two second connection terminals BOC2, while a second end face FE2 (j = 2) is without a second connection terminal BOC2.

[0039] The two second BOC2 connection terminals of each CE cell are respectively connected to corresponding second BOC2 connection terminals of neighboring CE cells via inter-cell conductive lines LC2.

[0040] Each CE cell can also be equipped with a second electronic board CE2 responsible for controlling its operation and intended to be coupled to the first electronic board IEC of its MC module. In the example illustrated, but not limited to, in [Fig. 2], each second electronic board CE2 is installed on the end face FE1 of a CE cell, but this is not mandatory.

[0041] It should be noted that in the examples illustrated, but not limited to, in Figures 2 and 3, the first dimension dl is larger than the second dimension d2. However, in an alternative embodiment not shown, the first dimension dl could be smaller than the second dimension d2.

[0042] For example, each CE cell can be electrochemical. In this case, it can, for example, be of the lithium-ion (or Li-ion) or Ni-MH or Ni-Cd type. Also, for example, a BC cellular battery, equipped with modules comprising CE cells, It can be of the low voltage type (typically 450 V as an example). But it could also be of the medium voltage or high voltage type.

[0043] As mentioned above, the invention notably proposes an assembly method intended to allow the assembly of MC modules intended to equip a BC cellular battery.

[0044] This (assembly) process can, for example, be carried out by an assembly plant (not shown) under the control of a DC control device (illustrated in [Fig. 4]). However, it could also be carried out manually by a technician.

[0045] This DC control device comprises at least one PR1 processor, for example a digital signal processor (or DSP), and at least one MD memory. It can therefore be implemented as a combination of electrical or electronic circuits or components (or "hardware") and software modules (or "software"). For example, it could be a microcontroller.

[0046] The MD memory is random access memory (RAM) for storing instructions for the implementation (or control) by the PR1 processor of at least part of the assembly process. The PR1 processor may include integrated (or printed) circuits, or several integrated (or printed) circuits connected by wired or wireless connections. An integrated (or printed) circuit is defined as any type of device capable of performing at least one electrical or electronic operation.

[0047] In the example illustrated, but not limited to, in [Fig. 4], the DC control device is part of an IC computer intended to equip the assembly plant. However, it could include its own dedicated computer.

[0048] As illustrated non-limitingly in [Fig.5], the (assembly) method according to the invention includes a step 10-20 which is implemented each time an MC module is to be assembled.

[0049] This step 10-20 includes a substep 10 in which all the first sides cl of each CE cell (to be part of an MC module) are positioned according to the same spatial orientation. This spatial orientation is chosen from among first and second spatial orientations that are perpendicular to each other, depending on whether the rigid shell ER has a third dimension d3 (following the installation direction of the CE cells) that corresponds to the first dimension dl of the CE cells or to the second dimension d2 of the CE cells.

[0050] It should be noted that the CE cells of an MC module during assembly can be positioned on a lower rigid plate of the future rigid ER envelope.

[0051] In other words, when the rigid shell ER has a third dimension d3 that corresponds to the first dimension dl of the CE cells, all these CE cells are positioned in the first spatial orientation (i.e., here, with all the first sides cl parallel to the Z direction), as illustrated in [Fig. 2]. Conversely, when the rigid envelope ER has a third dimension d3 which corresponds to the second dimension d2 of the CE cells, all these CE cells are positioned in the second spatial orientation (i.e., here, with all the first sides cl parallel to the X direction), as illustrated in [Fig.3].

[0052] The word "corresponding" here means "of the order of, by value greater than". Thus, when the third dimension d3 corresponds to the first dimension dl, this means that d3 is slightly larger than dl (in this case, the rigid enclosure ER must be able to accommodate at least the second connection terminals BOC2 with the inter-cell conductive lines LC2).

[0053] Step 10-20 also includes a substep 20 in which a rigid ER envelope is defined around the positioned CE cells.

[0054] For this purpose, in substep 20, for example, the CE cells positioned with lateral rigid plates can be compressed and then welded to the lower rigid plate to define the rigid enclosure ER, then, after defining the inter-cell conductive lines LC2 and fixing any second electronic boards CE2, temperature sensors and voltage sensors, a top cover of the rigid enclosure ER can be installed.

[0055] Thus, first MC modules can be made having a first third dimension d3 corresponding to the first dimension d1, and second MC modules can be made having a second third dimension d3 corresponding to the second dimension d2. The first MC modules (with their CE cells oriented according to the first spatial orientation) are then intended to be part of a first cell battery BC having a first height slightly greater than the first third dimension d3, while the second MC modules (with their CE cells oriented according to the second spatial orientation perpendicular to the first spatial orientation) are then intended to be part of a second cell battery BC having a second height slightly greater than the second third dimension d3. In the examples illustrated in Figures 2 and 3, the "height" (d3) of the rigid shell ER ([Fig. 2]) is therefore greater than the "height" (d3) of the rigid shell ER ([Fig. 3]).3] ), because the first dimension dl is strictly greater than the second dimension d2. .

[0056] It is therefore now possible to vary not only the "length" (Y) and "width" (X) of the MC modules, but also the "height" (Z) of these MC modules, which allows the design of BC cell batteries of different heights adapted to vehicles of different types, without this causing a complexification of the internal architecture of the BC cell batteries or of empty areas in the latter (BC) because the internal space can be occupied optimally with MC modules comprising CE cells all having the first or second spatial orientation.

[0057] It should be noted that when the assembly is at least partially automated in an assembly plant, it is the DC control device of the latter which can trigger each positioning, by the assembly plant, of all the first sides cl of the CE cells according to the same spatial orientation for the same MC module.

[0058] To this end, the assembly installation may include at least one robotic arm designed to successively grasp CE cells placed in a storage location and to position these successively grasped CE cells (for example, on a rigid wall of a future rigid ER enclosure) according to the same spatial orientation chosen from the first and second spatial orientations. If a first MC module is to be formed, the robotic arm is controlled so that it positions all the CE cells of the MC module in the first spatial orientation, and if a second MC module is to be formed, the robotic arm is controlled so that it positions all the CE cells of the MC module in the second spatial orientation (which requires it to rotate by + / - 90° relative to what it must do for a first MC module).

[0059] Next, we control the (each) robotic arm so that it defines the rigid envelope ER around the CE cells that have just been positioned.

[0060] Each robotic arm is controlled by the DC control device. For example, each MC module being assembled can be temporarily placed on a conveyor belt in the assembly installation.

[0061] It will be noted, as illustrated non-limitingly on [Fig.5], that step 10-20 is repeated as many times as there are MC modules to be assembled successively.

[0062] For example, when the third dimension d3 is along a direction of installation of the CE cells (for example on a rigid wall of a future rigid ER envelope) which is intended to be parallel to the vertical direction (here Z), in step 10-20, the first spatial orientation may be intended to be parallel to this vertical installation direction (here Z) (dl parallel to d3) (see [Fig.2]), and the second spatial orientation may be intended to be parallel to a horizontal direction (here X or Y) which is perpendicular to this vertical installation direction (here Z) (dl perpendicular to d3) (see [Fig.3]).

[0063] It should also be noted that in step 10-20 the CE cells can be positioned one behind the other in at least one row which is perpendicular to the direction of installation of the CE cells (for example on a rigid wall of a future rigid ER envelope).

[0064] In this case, in step 10-20, when each CE cell has its first end face FE1 equipped with two second connection terminals BOC2 and a second end face FE2 without a second connection terminal BOC2, one can po positioning (for example, the DC control device can trigger a positioning of) all the CE cells with their first end faces FE1 in the same plane perpendicular to the direction of installation (and therefore here oriented upwards). This is illustrated, but not limited to, in [Fig.2].

[0065] Alternatively, in step 10-20, when each CE cell has its first end face FE1 equipped with two second connection terminals BOC2 and a second end face FE2 without a second connection terminal BOC2, it is possible to position (for example, the DC control device can trigger a positioning of) all the CE cells belonging to two adjacent and parallel rows, with their second FE2 or first FE1 end faces facing each other and parallel to the direction of installation. Thus, in the second example of [Fig. 3], the CE cells belonging to two adjacent and parallel rows have their second end faces FE2 facing each other. But in an alternative, the CE cells belonging to two adjacent and parallel rows can have their first end faces FE1 facing each other.

[0066] It should also be noted, as illustrated in Figure 1, that the IC (or the DC control device's computer) may also include a mass storage MM1, in particular for storing the required spatial orientation, as well as any intermediate data involved in all its calculations and processing. Furthermore, this IC (or the DC control device's computer) may also include an input interface IE for receiving at least the required spatial orientation for use in calculations or processing, possibly after it has been shaped and / or demodulated and / or amplified, in a manner known per se, by means of a digital signal processor PR2. In addition, this IC (or the DC control device's computer) may also include an output interface IS, in particular for delivering each message (or command) for controlling the articulated arm.

[0067] It will also be noted that the invention also proposes a computer program product (or computer program) comprising a set of instructions which, when executed by processing means of the type of electronic circuits (or hardware), such as for example the PR1 processor, is suitable for implementing at least partially the assembly process described above for assembling MC modules intended to be part of BC cellular battery(ies).

Claims

Claims

1. Method for assembling a module (MC) suitable for forming part of a cellular battery (BC) and comprising a rigid casing (ER) in which are housed at least two identical electrical energy storage cells (CE), having a non-cubic parallelepiped shape, and each with i) first and second pairs of opposite lateral faces (FLk) and each comprising two first sides and two second sides having respectively first and second different dimensions, and ii) two opposite end faces (FEj) perpendicular to said lateral faces (FLk), characterized in that it comprises a step (10-20) in which i) all said first sides are positioned according to the same spatial orientation, chosen from first and second perpendicular spatial orientations depending on whether said rigid casing (ER) has a third dimension, in a direction of installation of said cells (CE),corresponding to said first dimension or to said second dimension, then ii) this rigid envelope (ER) is defined around said positioned cells (CE).,

2. A method according to claim 1, characterized in that in said step (10-20), when said third dimension is intended to be parallel to a vertical installation direction, said first and second spatial orientations are intended to be respectively parallel to said vertical installation direction, and to a horizontal direction perpendicular to said vertical installation direction.

3. Method according to claim 1 or 2, characterized in that in said step (10-20) said cells (CE) are positioned one behind the other in at least one row perpendicular to said installation direction.

4. Method according to one of claims 1 to 3, characterized in that in said step (10-20), when each cell (CE) has a first end face (FE1) provided with two connection terminals (BOC2) and a second end face (FE2) without a connection terminal (BOC2), all the cells (CE) are positioned with their first end faces (FE1) in the same plane perpendicular to said installation direction.

5. Method according to one of claims 1 to 3, characterized in that in said step (10-20), when each cell (CE) has a first end face (FE1) provided with two connection terminals (BOC2) and a second end face (FE2) without a connection terminal (BOC2), the cells (CE) belonging to two neighboring rows are positioned parallel to each other with their second (FE2) or first (FE1) end faces placed opposite each other and parallel to said installation direction.

6. Computer program product comprising a set of instructions which, when executed by processing means, is capable of implementing the assembly method according to one of claims 1 to 5 for assembling a module (MC) capable of forming part of a cellular battery (BC) and comprising a rigid casing (ER) in which are housed at least two identical electrical energy storage cells (CE) having a non-cubic parallelepiped shape.

7. Control device (DC) for an assembly installation suitable for assembling a module (MC) suitable for forming part of a cellular battery (BC) and comprising a rigid casing (ER) in which are housed at least two identical electrical energy storage cells (CE), having a non-cubic parallelepiped shape, and each with i) first and second pairs of opposite lateral faces (FLk) and each comprising two first sides and two second sides having respectively first and second different dimensions, and ii) two end faces (FEj) opposite and perpendicular to said lateral faces (FLk), characterized in that it comprises at least one processor (PR1) and at least one memory (MD) arranged to carry out the operations consisting in triggering i) a positioning, by said assembly installation, of all said first sides according to the same spatial orientation,chosen from first and second perpendicular spatial orientations depending on whether said rigid envelope (ER) has a third dimension, along a direction of installation of said cells (CE), corresponding to said first dimension or to said second dimension, then ii) a definition, by said assembly installation, of said rigid envelope (ER) around said positioned cells (CE).,

8. Assembly installation for assembling modules (MC) suitable for forming part of cellular battery(ies) (BC) and comprising a rigid casing (ER) in which are housed at least two identical electrical energy storage cells (CE), having a non-cubic parallelepiped shape, and each with i) first and second pairs of opposite side faces (FLk) and each comprising two first sides and two second sides having respectively first and second different dimensions, and ii) two end faces (FEj) opposite and perpendicular to said side faces (FLk), characterized in that it comprises a) at least one robotic arm capable of successively gripping cells (CE) placed in a storage location and of positioning all of said first sides according to the same spatial orientation, chosen from first and second perpendicular spatial orientations depending on whether said rigid envelope (ER) has a third dimension, along a direction of installation of said cells (CE), corresponding to said first dimension or to said second dimension, then of defining said rigid envelope (ER) around said positioned cells (CE), and b) a control device (DC) according to claim 7, capable of controlling said robotic arm.

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