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WO2024120764A1 - High-voltage battery with a sensor unit for detecting a deformation and/or shifting of a battery cell, motor vehicle with a high-voltage battery and method for determining a deformation within a high-voltage battery - Google Patents

High-voltage battery with a sensor unit for detecting a deformation and/or shifting of a battery cell, motor vehicle with a high-voltage battery and method for determining a deformation within a high-voltage battery Download PDF

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Publication number
WO2024120764A1
WO2024120764A1 PCT/EP2023/081722 EP2023081722W WO2024120764A1 WO 2024120764 A1 WO2024120764 A1 WO 2024120764A1 EP 2023081722 W EP2023081722 W EP 2023081722W WO 2024120764 A1 WO2024120764 A1 WO 2024120764A1
Authority
WO
WIPO (PCT)
Prior art keywords
voltage battery
battery
deformation
sensor
displacement
Prior art date
Application number
PCT/EP2023/081722
Other languages
German (de)
French (fr)
Inventor
Benjamin Bedürftig
Bastian Schaar
Christian Gert Voigt
Original Assignee
Audi Ag
Volkswagen Aktiengesellschaft
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Audi Ag, Volkswagen Aktiengesellschaft filed Critical Audi Ag
Publication of WO2024120764A1 publication Critical patent/WO2024120764A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
    • B60L3/0007—Measures or means for preventing or attenuating collisions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
    • B60L3/0023—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
    • B60L3/0046—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to electric energy storage systems, e.g. batteries or capacitors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
    • B60L3/0023—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
    • B60L3/0069—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to the isolation, e.g. ground fault or leak current
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
    • B60L3/12—Recording operating variables ; Monitoring of operating variables
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/64—Constructional details of batteries specially adapted for electric vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
    • B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
    • B60L58/16—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries responding to battery ageing, e.g. to the number of charging cycles or the state of health [SoH]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
    • B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
    • B60L58/18—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries of two or more battery modules
    • B60L58/21—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries of two or more battery modules having the same nominal voltage
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
    • G01B21/32—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring the deformation in a solid
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2200/00—Type of vehicles
    • B60L2200/12—Bikes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2200/00—Type of vehicles
    • B60L2200/18—Buses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2200/00—Type of vehicles
    • B60L2200/36—Vehicles designed to transport cargo, e.g. trucks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2240/00—Control parameters of input or output; Target parameters
    • B60L2240/40—Drive Train control parameters
    • B60L2240/54—Drive Train control parameters related to batteries
    • B60L2240/545—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2250/00—Driver interactions
    • B60L2250/10—Driver interactions by alarm
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01P—MEASURING LINEAR OR ANGULAR SPEED, ACCELERATION, DECELERATION, OR SHOCK; INDICATING PRESENCE, ABSENCE, OR DIRECTION, OF MOVEMENT
    • G01P15/00—Measuring acceleration; Measuring deceleration; Measuring shock, i.e. sudden change of acceleration
    • G01P15/02—Measuring acceleration; Measuring deceleration; Measuring shock, i.e. sudden change of acceleration by making use of inertia forces using solid seismic masses
    • G01P15/08—Measuring acceleration; Measuring deceleration; Measuring shock, i.e. sudden change of acceleration by making use of inertia forces using solid seismic masses with conversion into electric or magnetic values
    • G01P15/0891—Measuring acceleration; Measuring deceleration; Measuring shock, i.e. sudden change of acceleration by making use of inertia forces using solid seismic masses with conversion into electric or magnetic values with indication of predetermined acceleration values
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/4285—Testing apparatus
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2220/00—Batteries for particular applications
    • H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane

Definitions

  • the invention relates to a high-voltage battery for a motor vehicle with a sensor device for detecting a deformation and/or displacement of a battery cell, a motor vehicle with such a high-voltage battery and a method for determining a deformation within a high-voltage battery.
  • battery cells such as lithium-ion cells
  • packaging forms such as round cells, prismatic cells or pouch cells, which can be combined to form cell modules.
  • Cell modules and high-voltage batteries are currently subjected to various service life tests with corresponding compression factors, in which compliance with a defined external dimension inside and outside the high-voltage battery is checked.
  • Mechanical tests are also used to ensure that cell modules meet passing criteria, such as safety requirements, up to a defined load. These include compliance with an installation space dimension, no displacement of battery cells and compliance with air and creepage distances.
  • the service life is determined by a mixture of different loads. For example, calendar aging of the battery cells, mechanical deformations due to swelling during cycling, ambient temperature and electrical charging parameters. In addition, there are mechanical loads such as shock and vibration. Such loads cannot be reproduced in their complete combination in a lifespan test.
  • the problem is to detect the effect of aging of the battery cells and the so-called swelling during operation of the high-voltage battery and to determine the aging state of the high-voltage battery.
  • a status display device for a rechargeable motor vehicle battery which has a battery body arranged in a housing and which is subject to an aging process.
  • the battery body has a sensor that responds to an aging-related volume change in the battery and delivers a corresponding output signal.
  • a battery device wherein a plurality of individual cells having a cuboid shape, which are positioned with a predetermined gap, are arranged mutually in such a way that the side walls having the largest area in the individual cells are arranged opposite each other, and which has a swelling detecting element which is arranged in a gap between the individual cells almost near the center of the largest side walls in the individual cells and which functions to transform by swelling.
  • a high-voltage battery with a battery cell swelling sensor wherein the battery module has a cell module frame in which the cell stack is arranged and which has two metallic end pressure plates arranged on the end faces of the cell stack, and at least one electrically insulating spacer which is arranged between at least one of the end faces of the cell stack and the respective end pressure plate and capacitively couples the end face and the end pressure plate to form a plate capacitor, wherein an evaluation device for this purpose is designed to detect the expansion of at least one battery cell by means of capacity measurement.
  • the object of the invention is to determine the condition of the high-voltage battery in an improved manner.
  • the invention provides a high-voltage battery for a motor vehicle, comprising a plurality of battery cells arranged in at least one cell module having a housing, and at least one sensor device, wherein the sensor device is designed to detect a mechanical deformation and/or a displacement of at least one of the battery cells in any spatial direction and to provide a control signal upon detection of the deformation and/or displacement.
  • the high-voltage battery has a plurality of battery cells, which are arranged one behind the other in a housing, for example, and are thus combined to form a cell module.
  • one or more sensor devices can be provided in or on the cell module, for example on/in a housing wall of the cell module.
  • the sensor device can be configured to detect a deformation and/or displacement of the battery cells to the housing of the cell module to detect, preferably in all spatial directions. This means that the sensor device can determine whether the deformation and/or displacement of a respective battery cell occurs in the x, y and/or z direction.
  • at least one sensor can be provided which covers all spatial directions and which is preferably arranged in the middle of the cell module, since this is where the area with the greatest displacement of battery cells is located and which can determine at least half of the swelling path in the event of swelling.
  • at least three sensors can be provided which can determine a respective spatial direction and/or a respective sensor can be provided on end plates of the cell module in order to detect an expansion of battery cells.
  • the sensor device can, for example, have a contact sensor that is in contact with at least one battery cell and the housing of the cell module. If the battery cell shifts in relation to the housing, the contact sensor can detect this shift and trigger the control signal.
  • the contact can be triggered here, for example, by swelling or enlargement of one of the battery cells due to age, in which the battery cell swells and is thus either shifted itself or shifts another battery cell.
  • one or more of the battery cells can be shifted in the event of a shock or vibration, for example in the event of a motor vehicle accident, thus triggering the sensor device.
  • the sensor device can also have a contactless sensor, in particular an optical sensor and/or a capacitive sensor and/or an inductive sensor, which can, for example, determine a displacement and/or a distance of the battery cell from the housing.
  • a degree of deformation and/or displacement can also be determined by the sensor device. This means that it can preferably be determined by what distance a battery cell has moved.
  • the control signal that is provided when the deformation and/or displacement is detected can be used to control a warning device in the motor vehicle, for example to indicate that the high-voltage battery is damaged.
  • the control signal can be used to deactivate the high-voltage battery, in particular when the battery cells are under a heavy load. This means that, for example, electrical contacts that connect the battery cells and/or cell modules can be released using the control signal in order to electrically decouple the battery cells and/or cell modules.
  • the invention has the advantage that mechanical changes relevant to functional safety can be read out over the service life of the high-voltage battery. This means that both aging effects caused by swelling and deformations due to accidents can be detected without having to open the high-voltage battery. In addition, the degree of damage to the high-voltage battery can be better detected, meaning that the high-voltage battery only needs to be replaced after an accident if unacceptable internal deformations are detected.
  • the invention also includes further developments which result in additional advantages.
  • a further development provides that at least one sensor device is provided for each battery cell.
  • at least as many sensor devices can be provided for the cell module as battery cells. This results in the advantage that each battery cell can be monitored individually, making it possible to detect whether the deformation and/or displacement affects only one or several battery cells.
  • the sensor device is arranged in the middle of the top side of the housing.
  • the sensor device is preferably arranged at the level of the middle battery cell on the top.
  • the greatest force can occur on the battery cell in the middle of the cell module, which means that the battery cell arranged in the middle is most likely to shift. But even if other battery cells are shifted and/or deformed, this can have an effect on the middle battery cell, as this can then also be moved away from its original position, which can be measured by the sensor device. In this way, a statement can be made about the entire cell module.
  • the respective sensor device is a contact sensor.
  • the sensor device can be in physical contact with the respective battery cell. If the battery cell is displaced, this can be measured via a change in the physical contact.
  • at least one piezoelectric sensor can be used for this, which is designed to detect the displacement in any spatial direction.
  • a distance can be provided between the respective battery cell and the sensor device, wherein in the event of a displacement and/or deformation, the distance is bridged and the sensor device is triggered by contact.
  • a switch preferably a pressure switch, can be used for this purpose, wherein preferably a switch is arranged in each spatial direction in order to determine the displacement in each spatial direction.
  • the respective sensor device has an optical sensor and/or a capacitive sensor and/or an inductive sensor.
  • the sensor device can be designed as a contactless sensor, in particular as a light barrier and/or via a time-of-flight measurement of a light or laser pulse, with which a distance of one or more battery cells from the housing can be determined.
  • a suitable marking can also be provided on one or more battery cells, which can be checked or scanned by the optical sensor, which can also be designed as a camera, for example.
  • a capacitive sensor and/or an inductive sensor can also be provided, which is arranged, for example, in a housing of the cell module and which measures a corresponding capacitive and/or inductive signal between the sensor device and the surface of the battery cell.
  • the signal changes accordingly, whereby the displacement, and in particular the direction, can be determined.
  • a corresponding surface element can be arranged on the surface of the respective battery cell, for example a metal plate, whereby at least one induction coil of the inductive sensor and/or a capacitor plate of the capacitive sensor can detect the change by moving the metal plate.
  • an acoustic sensor can be used, in particular an ultrasonic sensor, to carry out a distance measurement and thus detect a deformation and/or displacement of one of the battery cells. This allows a further preferred embodiment to be achieved.
  • the respective sensor device is designed to determine a distance of the deformation and/or displacement. This means that preferably not only a displacement of the battery cell is detected, but also an absolute value is determined as to how far and in which direction the Battery cell has shifted.
  • This value determined by the displacement sensor can, for example, also be transmitted by means of the control signal in order to obtain a statement about the deformation and/or displacement, in particular about deformations inside and outside the cell module.
  • a "state of health" of the high-voltage battery or the cell modules can be provided, which can be used to determine, for example, whether the high-voltage battery should be replaced and/or what state of aging the high-voltage battery is in.
  • the displacement sensor can also comprise a force sensor, by means of which it can be determined whether a force threshold value was exceeded during the deformation and/or displacement or by how far the force threshold value was exceeded. In this way, further information can be made about the state of the high-voltage battery.
  • the cell module has an acceleration sensor which is designed to provide an acceleration value to the cell module when the deformation and/or displacement of the battery cells is detected by means of the sensor device.
  • This acceleration value can then preferably be supplied with the control signal, whereby an evaluation unit of the high-voltage battery can check this for exceeding a predetermined acceleration threshold value.
  • Acceleration values within the cell module can also be compared, for example, from which displacements of individual positions can be calculated.
  • several acceleration threshold values can be specified, whereby, for example, a first acceleration threshold value is smaller than a second acceleration threshold value, whereby only a warning message is generated when the first acceleration threshold value is exceeded and the high-voltage battery is deactivated when the second acceleration threshold value is exceeded.
  • the acceleration sensor can preferably be designed to measure the acceleration in all spatial directions (x, y and z) or three individual acceleration sensors can be provided, with each of these acceleration sensors determining the acceleration in one spatial direction. This further development has the advantage that a more precise statement can be made about the deformation and/or displacement of the cell module.
  • control signal is configured to deactivate the high-voltage battery and/or to provide a warning message using the control signal.
  • the control signal can also control a warning device in the motor vehicle to issue a warning message.
  • a defined short circuit is generated when one of the battery cells is deformed, which shuts down the battery, and/or one or more balancing contacts can be separated using a defined predetermined breaking point in the event of excessive deformation and/or displacement, which shuts down or deactivates the battery.
  • a further aspect of the invention relates to a method for determining a deformation of battery cells in a high-voltage battery, comprising the aforementioned high-voltage battery, wherein in the event of a deformation and/or displacement of at least one of the plurality of battery cells of the high-voltage battery in any spatial direction, the sensor device detects this deformation and/or displacement in the respective spatial direction, whereby a control signal is then generated with which a warning device of a motor vehicle and/or the high-voltage battery is controlled to deactivate the high-voltage battery.
  • a control signal is then generated with which a warning device of a motor vehicle and/or the high-voltage battery is controlled to deactivate the high-voltage battery.
  • a motor vehicle with a high-voltage battery mentioned above is also provided.
  • the motor vehicle according to the invention is preferably designed as a motor vehicle, in particular as a passenger car or truck, or as a passenger bus or motorcycle.
  • the principle of the high-voltage battery can be transferred to other applications, for example for batteries in smartphones or storage devices for solar systems.
  • the invention also includes the control device for the motor vehicle.
  • the control device can have a data processing device or a processor device that is set up to carry out an embodiment of the method according to the invention.
  • the processor device can have at least one microprocessor and/or at least one microcontroller and/or at least one FPGA (Field Programmable Gate Array) and/or at least one DSP (Digital Signal Processor).
  • the processor device can have program code that is set up to carry out the embodiment of the method according to the invention when executed by the processor device.
  • the program code can be stored in a data memory of the processor device.
  • a processor circuit of the processor device can, for example, have at least one circuit board and/or at least one SoC (System on Chip).
  • the invention also includes further developments of the method according to the invention which have features as have already been described in connection with the further developments of the high-voltage battery according to the invention. For this reason, the corresponding further developments of the method according to the invention are not described again here.
  • the invention also includes a computer-readable storage medium, comprising instructions which, when executed by a computer or a computer network, cause it to carry out an embodiment of the method according to the invention.
  • the storage medium can, for example, be designed at least partially as a non-volatile data memory (e.g. as a flash memory and/or as an SSD - solid state drive) and/or at least partially as a volatile data memory (e.g. as a RAM - random access memory).
  • the storage medium can also, for example, be operated as a so-called app store server on the Internet.
  • the computer or computer network can provide a processor circuit with at least one microprocessor.
  • the instructions can be provided as binary code or assembler and/or as source code of a programming language (e.g. C).
  • the invention also includes combinations of the features of the described embodiments.
  • the invention therefore also includes implementations that each have a combination of the features of several of the described embodiments, provided that the embodiments have not been described as mutually exclusive.
  • Fig. 1 is a schematic side view of a high-voltage battery in a motor vehicle according to an exemplary embodiment
  • Fig. 2 is a schematic plan view of a cell module of the high-voltage battery
  • Fig. 3 a cell module of the high-voltage battery in an exemplary situation
  • Fig. 4 a cell module of the high-voltage battery in another exemplary situation.
  • Fig. 1 shows a highly schematic motor vehicle 10 with a schematic side view of a high-voltage battery 12.
  • the high-voltage battery 12 which can be designed as a traction battery of the motor vehicle 10, comprises several battery cells 16, which can be combined to form a cell module 13, preferably stacked one behind the other.
  • the cell module 13 can have lateral end plates 15, in particular with a module screw connection 17, and a busbar carrier 14 at the top, which electrically connects the battery cells 16 to one another.
  • the cell module 13 can have further housing elements that are not explicitly shown here.
  • the high-voltage battery 12 can also comprise further cell modules 13, which are also not shown in this figure for reasons of clarity.
  • a sensor device 18 can be provided which is designed to detect deformation and/or displacement of the battery cells 16.
  • the sensor device 18 can be mounted, for example, on Height of the middle battery cell 16 in the busbar carrier 14 or a housing of the cell module 13.
  • several sensor devices 18 can be provided (not shown in this figure), in particular one for each battery cell 16, wherein the several sensor devices 18 can be provided for example in the busbar carrier 14 above the respective battery cell 16 and/or on side walls or the end plates 15.
  • the sensor device 18 can be designed to detect a deformation and/or displacement of the respective battery cell 16 in any spatial direction.
  • the sensor device 18 can be designed, for example, as a contactless sensor, in particular an inductive sensor, wherein the sensor device 18 can have, for example, induction coils 20 (not shown in this figure).
  • a surface element 19 corresponding to the induction coils 20 can also be provided on the respective battery cell 16, which is designed, for example, as a metal plate. If the surface element 19 is displaced in relation to the induction coils of the sensor device 18, a current signal is generated that is characteristic of the direction of displacement.
  • the sensor device 18 can be designed as a capacitive sensor, optical sensor or as a contact sensor that is in contact with the battery cell 16 and can detect a relative movement of the battery cell to the housing or the busbar carrier 14. If such a displacement is detected by the sensor device 18, a control signal can be provided.
  • the control signal can be used to control a warning device (not shown) of the motor vehicle 10, for example a screen that can indicate damage to the cell module 13.
  • the high-voltage battery 12 and/or the cell module 13 can also be deactivated by means of the control signal, for example by releasing contacts of the high-voltage battery 12 and/or the cell module 13 by means of electrically controlled switches.
  • the sensor device 18 can also be designed to determine a distance of displacement of the battery cell. This means that the sensor device 18 can determine how far the battery cell 16 has shifted compared to an original position. This allows an improved statement to be made about the type of damage and/or deformation.
  • the cell module 13 can also have at least one acceleration sensor 22 that can measure an acceleration value.
  • the sensor device 18 detects a displacement, the associated acceleration forces can be determined, whereby it can be determined whether the acceleration is above a predetermined acceleration threshold value or what value the acceleration has. This makes it easier to draw conclusions about possible damage to the cell module 13.
  • Fig. 2 shows a schematic top view of the cell module 13 of the high-voltage battery 12.
  • the busbar carrier 14 can be seen here, which includes busbars/cell connectors 24.
  • the induction coils 20 of the sensor device 18 designed as an inductive sensor are shown, wherein the surface element 19, which is arranged on the middle battery cell 16, can be located centrally between the induction coils 20 when the cell module 13 is undamaged.
  • the cell module 13 of the high-voltage battery 12 is shown in an exemplary situation in which at least one battery cell 16 has experienced a strong volume expansion due to an aging process, the so-called swelling.
  • the schematic side view is shown in the upper half of Fig. 3 and the schematic top view in the lower half. Due to the volume expansion of at least one of the battery cells 16, all battery cells 16 in the cell module 13 can shift, whereby in particular the end plates 15 can be pushed outwards.
  • the busbar carrier 14 is only connected to one of the end plates 15 on one side. is connected, as shown here for example on the left side.
  • a displacement of the battery cells 16 takes place mainly to the right side, where the end plate 15 is pressed out.
  • the surface element 19 can be moved in the direction of expansion, whereby a signal measured by the induction coils 20 of the sensor device 18 changes accordingly. Due to the change in the signal measured by the induction coils 20, the sensor device 18 can detect the deformation and/or displacement and generate a control signal with which the high-voltage battery 12 can be controlled, in particular for deactivation. Alternatively or additionally, a warning device (not shown) of the motor vehicle 10 can be controlled with the control signal in order to issue a warning message. It can therefore be determined that at least the cell module 13 must be replaced due to an aging process without first having to open the high-voltage battery 12.
  • an acceleration sensor 22 is provided for the cell module 13, it can be determined that no large accelerations occurred on the cell module 13 during swelling, whereby it can be concluded that the sensor device 18 was triggered due to an aging process of one of the battery cells 16 and not due to an impact or impulse.
  • the cell module 13 of the high-voltage battery 12 is shown in another exemplary situation, with the schematic side view again being shown in the upper half and the schematic top view in the lower half.
  • an accident of the motor vehicle 10 may occur, whereby high forces can act on the high-voltage battery 12 and thus on the battery cells 16 of the cell module 13, which can lead, for example, to a displacement of battery cells 16.
  • the middle battery cell 16 can be removed from the cell module 13. pushed out, as this is usually subject to the greatest forces.
  • This displacement of the battery cell 16 can be detected by the sensor device 18, since the battery cell 16, in particular the surface element 19, is displaced relative to the sensor device 18, in particular in the direction of one of the induction coils 20.
  • the sensor device 18 can thus detect the lateral displacement of the battery cell 16 and generate the control signal for deactivating the high-voltage battery 12 and/or for issuing a warning message.
  • the acceleration sensor 22 can detect an acceleration value, i.e. a force that acted on the cell module 13 during the displacement. Depending on the acceleration value, a decision can then be made, for example, as to whether only a warning signal is issued or whether the high-voltage battery 12 must be deactivated, in particular if the acceleration value is above an acceleration threshold value.
  • an acceleration value i.e. a force that acted on the cell module 13 during the displacement.
  • a decision can then be made, for example, as to whether only a warning signal is issued or whether the high-voltage battery 12 must be deactivated, in particular if the acceleration value is above an acceleration threshold value.
  • the examples show how the invention can provide a cell module safety sensor that can detect both an aging process and deformations due to accidents without opening the battery 12.

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Abstract

The invention relates to a high-voltage battery (12) for a motor vehicle (10) and a method for determining a deformation of the high-voltage battery (12). The high-voltage battery (12) comprises a plurality of battery cells (16) arranged in at least one cell module (13), and at least one sensor unit (18), wherein the sensor unit (18) is designed to detect a mechanical deformation and/or shifting of at least one of the battery cells (16) in each spatial direction, and to provide a control signal when the deformation and/or shifting is detected.

Description

Hochvoltbatterie mit einer Sensoreinrichtung zur Erfassung einer Verformung und/oder Verschiebung einer Batteriezelle, Kraftfahrzeug mit einer Hochvoltbatterie und Verfahren zum Ermitteln einer Deformation innerhalb einer Hochvoltbatterie High-voltage battery with a sensor device for detecting a deformation and/or displacement of a battery cell, motor vehicle with a high-voltage battery and method for determining a deformation within a high-voltage battery
BESCHREIBUNG: DESCRIPTION:
Die Erfindung betrifft eine Hochvoltbatterie für ein Kraftfahrzeug mit einer Sensoreinrichtung zur Erfassung einer Verformung und/oder Verschiebung einer Batteriezelle, ein Kraftfahrzeug mit einer solchen Hochvoltbatterie und ein Verfahren zum Ermitteln einer Deformation innerhalb einer Hochvoltbatterie. The invention relates to a high-voltage battery for a motor vehicle with a sensor device for detecting a deformation and/or displacement of a battery cell, a motor vehicle with such a high-voltage battery and a method for determining a deformation within a high-voltage battery.
In gängigen Hochvoltbatterien werden Batteriezellen, zum Beispiel Lithium- lonen-Zellen, in verschiedenen Packungsformen, zum Beispiel Rundzellen, prismatischen Zellen oder Pouchzellen verbaut, die zu Zellmodulen zusammengefasst werden können. Aktuell werden Zellmodule und Hochvoltbatterien unterschiedlichen Lebensdauertests mit entsprechenden Raffungsfaktoren unterzogen, bei denen die Einhaltung einer definierten Außenabmessung innerhalb und außerhalb der Hochvoltbatterie überprüft wird. Über mechanische Tests wird außerdem abgesichert, dass Zellmodule bis zu einer definierten Belastung Bestehungskriterien, beispielsweise Sicherheitsanforderungen, erfüllen. Hierzu gehören unter anderem die Einhaltung einer Bauraumabmessung, keine Verschiebung von Batteriezellen und Einhaltung von Luft- und Kriechstrecken. In common high-voltage batteries, battery cells, such as lithium-ion cells, are installed in various packaging forms, such as round cells, prismatic cells or pouch cells, which can be combined to form cell modules. Cell modules and high-voltage batteries are currently subjected to various service life tests with corresponding compression factors, in which compliance with a defined external dimension inside and outside the high-voltage battery is checked. Mechanical tests are also used to ensure that cell modules meet passing criteria, such as safety requirements, up to a defined load. These include compliance with an installation space dimension, no displacement of battery cells and compliance with air and creepage distances.
Bei einer realen Belastung der Zellmodule ergibt sich die Lebensdauer jedoch aus einer Mischung unterschiedlicher Belastungen. Zum Beispiel einer kalendarischen Alterung der Batteriezellen, mechanischen Deformationen durch Swelling bei Zyklisierung, Umgebungstemperatur und elektrischen Ladeparameter. Hinzu kommen mechanische Belastungen, wie Schock und Vibrationen. Solche Belastungen lassen sich in ihrer vollständigen Kombination nicht in Lebensdauertest nachbilden. However, when the cell modules are subjected to real loads, the service life is determined by a mixture of different loads. For example, calendar aging of the battery cells, mechanical deformations due to swelling during cycling, ambient temperature and electrical charging parameters. In addition, there are mechanical loads such as shock and vibration. Such loads cannot be reproduced in their complete combination in a lifespan test.
Daher besteht das Problem, den Effekt der Alterung der Batteriezellen und das so genannte Swelling in einem Betrieb der Hochvoltbatterie zu erkennen und den Alterungszustand der Hochvoltbatterie festzustellen. Therefore, the problem is to detect the effect of aging of the battery cells and the so-called swelling during operation of the high-voltage battery and to determine the aging state of the high-voltage battery.
Aus der DE 10 2009 025 373 A1 ist eine Zustandsanzeigevorrichtung für eine wiederaufladbare Kraftfahrzeug-Batterie bekannt, die einen in einem Gehäuse angeordneten Batteriekörper besitzt und die einem Alterungsprozess unterworfen ist. Der Batteriekörper besitzt einen Sensor, der auf eine alterungsbedingte Volumenänderung der Batterie anspricht und ein entsprechendes Ausgangssignal liefert. From DE 10 2009 025 373 A1, a status display device for a rechargeable motor vehicle battery is known, which has a battery body arranged in a housing and which is subject to an aging process. The battery body has a sensor that responds to an aging-related volume change in the battery and delivers a corresponding output signal.
Aus der EP 1 406 340 B1 ist eine Batterievorrichtung bekannt, wobei eine Vielzahl einzelner Zellen mit einer Quaderform, die mit einem vorgegebenen Zwischenraum positioniert sind, gegenseitig in einer Weise angeordnet sind, dass die Seitenwände mit der größten Fläche in den einzelnen Zellen gegenüber angeordnet sind, und die ein Element zum Erfassen eines Anschwellens, das in einem Zwischenraum zwischen den einzelnen Zellen fast in der Nähe der Mitte der größten Seitenwände in den einzelnen Zellen eingerichtet ist und das derart funktioniert, dass es sich durch Anschwellen umwandelt. From EP 1 406 340 B1 a battery device is known, wherein a plurality of individual cells having a cuboid shape, which are positioned with a predetermined gap, are arranged mutually in such a way that the side walls having the largest area in the individual cells are arranged opposite each other, and which has a swelling detecting element which is arranged in a gap between the individual cells almost near the center of the largest side walls in the individual cells and which functions to transform by swelling.
Aus der DE 10 2019 108 371 A1 ist eine Hochvoltbatterie mit einem Batteriezellenschwellungssensor bekannt, wobei das Batteriemodul einen Zellmodulrahmen aufweist, in welchen der Zellstapel angeordnet ist und welcher zwei metallische, an den Stirnseiten des Zellstapels angeordnete Enddruckplatten aufweist, und zumindest einen elektrisch isolierenden Abstandshalter, welcher zwischen zumindest einer der Stirnseiten des Zellstapels und der jeweiligen Enddruckplatte angeordnet ist und dabei die Stirnseite und die Enddruckplatte unter Ausbildung eines Plattenkondensators kapazitiv koppelt, wobei eine Auswerteeinrichtung dazu ausgelegt ist, die Ausdehnung der zumindest einen Batteriezelle mittels Kapazitätsmessung zu erkennen. From DE 10 2019 108 371 A1, a high-voltage battery with a battery cell swelling sensor is known, wherein the battery module has a cell module frame in which the cell stack is arranged and which has two metallic end pressure plates arranged on the end faces of the cell stack, and at least one electrically insulating spacer which is arranged between at least one of the end faces of the cell stack and the respective end pressure plate and capacitively couples the end face and the end pressure plate to form a plate capacitor, wherein an evaluation device for this purpose is designed to detect the expansion of at least one battery cell by means of capacity measurement.
Nachteilig bei diesen Hochvoltbatterien ist es, dass nur Alterungseffekte, insbesondere ein Swelling, erkannt werden kann. Jedoch können auch weitere Faktoren, wie beispielsweise Schock und Vibration zu einer Beschädigung innerhalb der Hochvoltbatterie führen. Diese können mit den zuvor genannten Methoden nicht zuverlässig erkannt werden, wenn die Zellmodule in der Hochvoltbatterie verbaut sind. The disadvantage of these high-voltage batteries is that only aging effects, particularly swelling, can be detected. However, other factors such as shock and vibration can also lead to damage within the high-voltage battery. These cannot be reliably detected using the methods mentioned above if the cell modules are installed in the high-voltage battery.
Daher ist es die Aufgabe der Erfindung, einen Zustand der Hochvoltbatterie verbessert zu ermitteln. Therefore, the object of the invention is to determine the condition of the high-voltage battery in an improved manner.
Diese Aufgabe wird durch die unabhängigen Patentansprüche gelöst. Vorteilhafte Weiterbildungen der Erfindung sind in den abhängigen Patentansprüchen, der folgenden Beschreibung sowie den Figuren offenbart. This object is achieved by the independent patent claims. Advantageous developments of the invention are disclosed in the dependent patent claims, the following description and the figures.
Durch die Erfindung ist eine Hochvoltbatterie für ein Kraftfahrzeug bereitgestellt, umfassend eine Mehrzahl von Batteriezellen, die in zumindest einem Zellmodul, das ein Gehäuse aufweist, angeordnet sind, und zumindest eine Sensoreinrichtung, wobei die Sensoreinrichtung dazu ausgebildet ist, eine mechanische Verformung und/oder eine Verschiebung von zumindest einer der Batteriezellen in jede Raumrichtung zu erfassen und bei Erfassen der Verformung und/oder Verschiebung ein Steuersignal bereitzustellen. The invention provides a high-voltage battery for a motor vehicle, comprising a plurality of battery cells arranged in at least one cell module having a housing, and at least one sensor device, wherein the sensor device is designed to detect a mechanical deformation and/or a displacement of at least one of the battery cells in any spatial direction and to provide a control signal upon detection of the deformation and/or displacement.
Mit anderen Worten weist die Hochvoltbatterie mehrere Batteriezellen auf, die beispielsweise hintereinander in einem Gehäuse angeordnet und so zu einem Zellmodul zusammengefasst sind. Zur Ermittlung einer Verformung und/oder einer Verschiebung einer oder mehrerer der Batteriezellen können insbesondere im oder am Zellmodul eine oder mehrere Sensoreinrichtungen bereitgestellt sein, beispielsweise an/in einer Gehäusewand des Zellmoduls. In other words, the high-voltage battery has a plurality of battery cells, which are arranged one behind the other in a housing, for example, and are thus combined to form a cell module. In order to determine a deformation and/or a displacement of one or more of the battery cells, one or more sensor devices can be provided in or on the cell module, for example on/in a housing wall of the cell module.
Die Sensoreinrichtung kann dazu konfiguriert sein, eine Verformung und/oder Verschiebung der der Batteriezellen zum Gehäuse des Zellmoduls zu erfassen, vorzugsweise in alle Raumrichtungen. Das bedeutet, dass die Sensoreinrichtung ermitteln kann, ob die Verformung und/oder Verschiebung einer jeweiligen Batteriezelle in x-, y- und/oder z-Richtung erfolgt. Dazu kann beispielsweise zumindest ein Sensor bereitgestellt sein, der alle Raumrichtungen abdeckt, und der vorzugsweise in der Mitte des Zellmoduls angeordnet ist, da dort der Bereich mit der größten Verschiebung von Batteriezellen vorliegt und der bei einem Swelling zumindest einen halben Swellingweg ermitteln kann. Alternativ oder zusätzlich können auch zumindest drei Sensoren bereitgestellt sein, die eine jeweilige Raumrichtung ermitteln können und/oder ein jeweiliger Sensor kann an Endplatten des Zellmoduls bereitgestellt werden, um eine Ausdehnung von Batteriezellen zu erkennen. The sensor device can be configured to detect a deformation and/or displacement of the battery cells to the housing of the cell module to detect, preferably in all spatial directions. This means that the sensor device can determine whether the deformation and/or displacement of a respective battery cell occurs in the x, y and/or z direction. For this purpose, for example, at least one sensor can be provided which covers all spatial directions and which is preferably arranged in the middle of the cell module, since this is where the area with the greatest displacement of battery cells is located and which can determine at least half of the swelling path in the event of swelling. Alternatively or additionally, at least three sensors can be provided which can determine a respective spatial direction and/or a respective sensor can be provided on end plates of the cell module in order to detect an expansion of battery cells.
Die Sensoreinrichtung kann beispielsweise einen Kontaktsensor aufweisen, der mit zumindest einer Batteriezelle und dem Gehäuse des Zellmoduls in Kontakt steht. Verschiebt sich die Batteriezelle in Relation zum Gehäuse kann der Kontaktsensor diese Verschiebung erfassen und das Steuersignal auslösen. Der Kontakt kann hier beispielsweise durch alterungsbedingtes Swelling beziehungsweise Vergrößern einer der Batteriezellen ausgelöst werden, indem die Batteriezelle anschwillt und so entweder selber verschoben wird oder eine weitere Batteriezelle verschiebt. Alternativ oder zusätzlich kann bei einem Schock beziehungsweise einer Vibration, beispielsweise bei einem Unfall des Kraftfahrzeugs, einer oder mehrere der Batteriezellen verschoben werden und somit die Sensoreinrichtung auslösen. The sensor device can, for example, have a contact sensor that is in contact with at least one battery cell and the housing of the cell module. If the battery cell shifts in relation to the housing, the contact sensor can detect this shift and trigger the control signal. The contact can be triggered here, for example, by swelling or enlargement of one of the battery cells due to age, in which the battery cell swells and is thus either shifted itself or shifts another battery cell. Alternatively or additionally, one or more of the battery cells can be shifted in the event of a shock or vibration, for example in the event of a motor vehicle accident, thus triggering the sensor device.
Als Alternative zum Kontaktsensor kann die Sensoreinrichtung auch einen berührungslosen Sensor aufweisen, insbesondere einen optischen Sensor und/oder einen kapazitiven Sensor und/oder einen induktiven Sensor, der beispielsweise eine Verschiebung und/oder einen Abstand der Batteriezelle zu dem Gehäuse ermitteln kann. Besonders bevorzugt kann auch ein Grad der Verformung und/oder Verschiebung durch die Sensoreinrichtung festgestellt werden. Das bedeutet, dass vorzugsweise festgestellt werden kann, um welche Strecke sich eine Batteriezelle bewegt hat. Durch die Erfassung einer Verformung/Verschiebung der Batteriezellen in jede Raumrichtung durch die Sensoreinrichtung ergibt sich der Vorteil, dass Stöße aus jeder Richtung und auch ein „Herausheben“ von Batteriezellen nach oben erfasst werden können. Somit ist es also nicht nur möglich, ein altersbedingtes Swelling zu erfassen, sondern auch Stöße und Vibrationen, die beispielsweise durch Unfälle des Kraftfahrzeugs ausgelöst werden. As an alternative to the contact sensor, the sensor device can also have a contactless sensor, in particular an optical sensor and/or a capacitive sensor and/or an inductive sensor, which can, for example, determine a displacement and/or a distance of the battery cell from the housing. Particularly preferably, a degree of deformation and/or displacement can also be determined by the sensor device. This means that it can preferably be determined by what distance a battery cell has moved. By detecting a deformation/displacement of the battery cells in any spatial direction using the sensor device, there is the advantage that impacts from any direction and also a "lifting" of battery cells upwards can be detected. This means that it is not only possible to detect age-related swelling, but also impacts and vibrations that are triggered by motor vehicle accidents, for example.
Das Steuersignal, das bei Erfassen der Verformung und/oder Verschiebung bereitgestellt wird, kann dabei verwendet werden, um eine Warneinrichtung des Kraftfahrzeugs anzusteuern, beispielsweise um anzuzeigen, dass die Hochvoltbatterie beschädigt ist. Alternativ oder zusätzlich kann das Steuersignal dazu verwendet werden, die Hochvoltbatterie zu deaktivieren, insbesondere bei einer starken Belastung der Batteriezellen. Das bedeutet, dass beispielsweise elektrische Kontakte, die die Batteriezellen und/oder Zellmodule verbinden, mittels des Steuersignals gelöst werden können, um die Batteriezellen und/oder Zellmodule elektrisch zu entkoppeln. The control signal that is provided when the deformation and/or displacement is detected can be used to control a warning device in the motor vehicle, for example to indicate that the high-voltage battery is damaged. Alternatively or additionally, the control signal can be used to deactivate the high-voltage battery, in particular when the battery cells are under a heavy load. This means that, for example, electrical contacts that connect the battery cells and/or cell modules can be released using the control signal in order to electrically decouple the battery cells and/or cell modules.
Durch die Erfindung ergibt sich der Vorteil, dass funktionssicherheitsrelevante mechanische Veränderungen über die Lebensdauer der Hochvoltbatterie ausgelesen werden können. Somit können sowohl Alterungseffekte durch Swelling als auch Deformationen aufgrund von Unfällen erkannt werden, ohne die Hochvoltbatterie öffnen zu müssen. Außerdem kann ein Grad einer Beschädigung der Hochvoltbatterie verbessert erkannt werden, wodurch die Hochvoltbatterie nach einem Unfall nur getauscht werden muss, wenn unzulässige interne Deformationen erkannt wurden. The invention has the advantage that mechanical changes relevant to functional safety can be read out over the service life of the high-voltage battery. This means that both aging effects caused by swelling and deformations due to accidents can be detected without having to open the high-voltage battery. In addition, the degree of damage to the high-voltage battery can be better detected, meaning that the high-voltage battery only needs to be replaced after an accident if unacceptable internal deformations are detected.
Die Erfindung umfasst auch Weiterbildungen, durch die sich zusätzliche Vorteile ergeben. The invention also includes further developments which result in additional advantages.
Eine Weiterbildung sieht vor, dass mindestens eine Sensoreinrichtung für jede Batteriezelle bereitgestellt ist. Mit anderen Worten können für das Zellmodul mindestens so viele Sensoreinrichtungen bereitgestellt sein wie Batteriezellen. Hierdurch ergibt sich der Vorteil, dass jede Batteriezelle einzeln überwacht werden kann, wodurch erkannt werden kann, ob die Verformung und/oder Verschiebung nur eine oder mehrere Batteriezellen betrifft. A further development provides that at least one sensor device is provided for each battery cell. In other words, at least as many sensor devices can be provided for the cell module as battery cells. This results in the advantage that each battery cell can be monitored individually, making it possible to detect whether the deformation and/or displacement affects only one or several battery cells.
In einer weiteren Weiterbildung ist vorgesehen, dass genau eine Sensoreinrichtung mittig an einer Oberseite des Gehäuses angeordnet ist. Das bedeutet, dass die Sensoreinrichtung vorzugsweise auf Höhe der mittleren Batteriezelle an der Oberseite angeordnet ist. Insbesondere bei Unfällen kann die größte Kraft auf die Batteriezelle in der Mitte des Zellmoduls auftreten, wodurch sich die in der Mitte angeordnete Batteriezelle am wahrscheinlichsten verschiebt. Aber auch bei einer Verschiebung und/oder Verformung von anderen Batteriezellen kann dies eine Auswirkung auf die mittlere Batteriezelle haben, da diese dann auch aus der ursprünglichen Position wegbewegt werden kann, was durch die Sensoreinrichtung gemessen werden kann. Somit kann eine Aussage über das gesamte Zellmodul getroffen werden. Durch diese Weiterbildung ergibt sich der Vorteil, dass Kosten gespart werden können, da Sensoreinrichtungen eingespart werden können. In a further development, it is provided that exactly one sensor device is arranged in the middle of the top side of the housing. This means that the sensor device is preferably arranged at the level of the middle battery cell on the top. In the event of an accident in particular, the greatest force can occur on the battery cell in the middle of the cell module, which means that the battery cell arranged in the middle is most likely to shift. But even if other battery cells are shifted and/or deformed, this can have an effect on the middle battery cell, as this can then also be moved away from its original position, which can be measured by the sensor device. In this way, a statement can be made about the entire cell module. This development has the advantage that costs can be saved because sensor devices can be saved.
Eine weitere Weiterbildung sieht vor, dass die jeweilige Sensoreinrichtung ein Kontaktsensor ist. Das bedeutet, dass die Sensoreinrichtung in physischen Kontakt mit der jeweiligen Batteriezelle stehen kann. Bei einer Verschiebung der Batteriezelle kann dies über eine Veränderung des physischen Kontakts gemessen werden. Beispielsweise kann dafür zumindest ein Piezoelektrischer Sensor verwendet werden, der dazu ausgebildet ist, die Verschiebung in jede Raumrichtung zu erfassen. Alternativ kann ein Abstand zwischen der jeweiligen Batteriezelle und der Sensoreinrichtung vorgesehen sein, wobei bei einer Verschiebung und/oder Verformung der Abstand überbrückt wird und die Sensoreinrichtung durch Kontakt auslöst. Hierzu kann insbesondere ein Schalter, vorzugsweise ein Druckschalter, verwendet werden, wobei vorzugsweise in jeder Raumrichtung ein Schalter angeordnet ist, um die Verschiebung in jede Raumrichtung zu bestimmen. Durch diese Weiterbildung kann eine Ausführungsform der Sensoreinrichtung bereitgestellt werden. Vorzugsweise ist in einer weiteren Weiterbildung vorgesehen, dass die jeweilige Sensoreinrichtung einen optischen Sensor und/oder einen kapazitiven Sensor und/oder einen induktiven Sensor aufweist. Mit anderen Worten kann die Sensoreinrichtung als berührungsloser Sensor ausgebildet sein, insbesondere als Lichtschranke und/oder über eine Laufzeitmessung eines Licht-/ beziehungsweise Laserpulses, mit dem ein Abstand einer oder mehrerer Batteriezellen zu dem Gehäuse ermittelt werden kann. Beispielsweise kann auch eine geeignete Markierung auf einer oder mehreren Batteriezellen bereitgestellt sein, die durch den optischen Sensor, der beispielsweise auch als Kamera ausgebildet sein kann, überprüft beziehungsweise abgetastet werden kann. Alternativ oder zusätzlich kann auch ein kapazitiver Sensor und/oder ein induktiver Sensor bereitgestellt sein, der Beispielsweise in einem Gehäuse des Zellmoduls angeordnet ist und der ein entsprechendes kapazitives und/oder induktives Signal zwischen der Sensoreinrichtung und der Oberfläche der Batteriezelle misst. Bei Verschiebung der Batteriezelle in eine Raumrichtung verändert sich das Signal entsprechend, wodurch die Verschiebung, und insbesondere die Richtung, festgestellt werden kann. Vorzugsweise kann an der Oberfläche der jeweiligen Batteriezelle ein korrespondierendes Flächenelement angeordnet sein, beispielsweise ein Metallplättchen, wobei durch eine Verschiebung des Metallplättchens zumindest eine Induktionsspule des induktiven Sensors und/oder eine Kondensatorplatte des kapazitiven Sensors die Veränderung feststellen kann. Als weitere Möglichkeit kann ein akustischer Sensor verwendet werden, insbesondere ein Ultraschallsensor, um eine Abstandsmessung durchzuführen und somit eine Verformung und/oder Verschiebung einer der Batteriezellen zu erkennen. Hierdurch kann eine weitere bevorzugte Ausführungsform erreicht werden. A further development provides that the respective sensor device is a contact sensor. This means that the sensor device can be in physical contact with the respective battery cell. If the battery cell is displaced, this can be measured via a change in the physical contact. For example, at least one piezoelectric sensor can be used for this, which is designed to detect the displacement in any spatial direction. Alternatively, a distance can be provided between the respective battery cell and the sensor device, wherein in the event of a displacement and/or deformation, the distance is bridged and the sensor device is triggered by contact. In particular, a switch, preferably a pressure switch, can be used for this purpose, wherein preferably a switch is arranged in each spatial direction in order to determine the displacement in each spatial direction. This development can provide an embodiment of the sensor device. Preferably, in a further development, it is provided that the respective sensor device has an optical sensor and/or a capacitive sensor and/or an inductive sensor. In other words, the sensor device can be designed as a contactless sensor, in particular as a light barrier and/or via a time-of-flight measurement of a light or laser pulse, with which a distance of one or more battery cells from the housing can be determined. For example, a suitable marking can also be provided on one or more battery cells, which can be checked or scanned by the optical sensor, which can also be designed as a camera, for example. Alternatively or additionally, a capacitive sensor and/or an inductive sensor can also be provided, which is arranged, for example, in a housing of the cell module and which measures a corresponding capacitive and/or inductive signal between the sensor device and the surface of the battery cell. When the battery cell is displaced in a spatial direction, the signal changes accordingly, whereby the displacement, and in particular the direction, can be determined. Preferably, a corresponding surface element can be arranged on the surface of the respective battery cell, for example a metal plate, whereby at least one induction coil of the inductive sensor and/or a capacitor plate of the capacitive sensor can detect the change by moving the metal plate. As a further possibility, an acoustic sensor can be used, in particular an ultrasonic sensor, to carry out a distance measurement and thus detect a deformation and/or displacement of one of the battery cells. This allows a further preferred embodiment to be achieved.
In einer weiteren Weiterbildung ist vorgesehen, dass die jeweilige Sensoreinrichtung dazu ausgebildet ist, eine Wegstrecke der Verformung und/oder Verschiebung zu bestimmen. Das bedeutet, dass vorzugsweise nicht nur eine Verschiebung der Batteriezelle erkannt wird, sondern auch ein Absolutwert ermittelt wird, wie weit und in welche Richtung sich die Batteriezelle verschoben hat. Dieser durch den Wegsensor ermittelte Wert kann beispielsweise auch mittels des Steuersignals übermittelt werden, um beispielsweise eine Aussage über die Verformung und/oder Verschiebung zu erhalten, insbesondere über Deformationen innerhalb und außerhalb des Zellmoduls. Somit kann ein „Gesundheitszustand“ der Hochvoltbatterie beziehungsweise der Zellmodule bereitgestellt werden, durch den beispielsweise ermittelt werden kann, ob die Hochvoltbatterie ausgetauscht werden soll und/oder in welchem Alterungszustand sich die Hochvoltbatterie befindet. Dieser „Gesundheitszustand“ kann dann beispielsweise bei einem Verkauf des Fahrzeugs mit angegeben werden. Besonders bevorzugt kann der Wegsensor auch einen Kraftsensor umfassen, mittels dem festgestellt werden kann, ob ein Kraftschwellenwert bei der Verformung und/oder Verschiebung überschritten wurde beziehungsweise wie weit der Kraftschwellenwert überschritten wurde. Somit kann eine weitere Aussage über den Zustand der Hochvoltbatterie getroffen werden. In a further development, it is provided that the respective sensor device is designed to determine a distance of the deformation and/or displacement. This means that preferably not only a displacement of the battery cell is detected, but also an absolute value is determined as to how far and in which direction the Battery cell has shifted. This value determined by the displacement sensor can, for example, also be transmitted by means of the control signal in order to obtain a statement about the deformation and/or displacement, in particular about deformations inside and outside the cell module. In this way, a "state of health" of the high-voltage battery or the cell modules can be provided, which can be used to determine, for example, whether the high-voltage battery should be replaced and/or what state of aging the high-voltage battery is in. This "state of health" can then be stated, for example, when the vehicle is sold. Particularly preferably, the displacement sensor can also comprise a force sensor, by means of which it can be determined whether a force threshold value was exceeded during the deformation and/or displacement or by how far the force threshold value was exceeded. In this way, further information can be made about the state of the high-voltage battery.
In einer bevorzugten Weiterbildung ist vorgesehen, dass das Zellmodul einen Beschleunigungssensor aufweist, der dazu ausgebildet ist, bei Erkennen der Verformung und/oder Verschiebung der Batteriezellen mittels der Sensoreinrichtung zusätzlich einen dabei auftretenden Beschleunigungswert auf das Zellmodul bereitzustellen. Dieser Beschleunigungswert kann dann vorzugsweise mit dem Steuersignal mitgeliefert werden, wobei eine Auswerteeinheit der Hochvoltbatterie diesen auf Überschreiten eines vorgegebenen Beschleunigungsschwellenwerts überprüfen kann. Auch können beispielsweise Beschleunigungswerte innerhalb des Zellmoduls verglichen werden, woraus sich Verschiebungen einzelner Positionen berechnen lassen. Besonders bevorzugt können mehrere Beschleunigungsschwellenwerte vorgegeben werden, wobei beispielsweise ein erster Beschleunigungsschwellenwert kleiner als ein zweiter Beschleunigungsschwellenwert ist, wobei bei Überschreiten des ersten Beschleunigungsschwellenwertes nur eine Warnmeldung erzeugt wird und bei Überschreiten des zweiten Beschleunigungsschwellenwertes die Hochvoltbatterie deaktiviert wird. Der Beschleunigungssensor kann vorzugsweise dazu ausgebildet sein, die Beschleunigung in alle Raumrichtungen (x, y und z) zu messen oder es können drei einzelne Beschleunigungssensoren bereitgestellt sein, wobei ein jeweiliger dieser Beschleunigungssensoren die Beschleunigung in einer Raumrichtung bestimmt. Durch diese Weiterbildung ergibt sich der Vorteil, dass eine genauere Aussage über die Verformung und/oder Verschiebung des Zellmoduls getroffen werden kann. In a preferred development, it is provided that the cell module has an acceleration sensor which is designed to provide an acceleration value to the cell module when the deformation and/or displacement of the battery cells is detected by means of the sensor device. This acceleration value can then preferably be supplied with the control signal, whereby an evaluation unit of the high-voltage battery can check this for exceeding a predetermined acceleration threshold value. Acceleration values within the cell module can also be compared, for example, from which displacements of individual positions can be calculated. Particularly preferably, several acceleration threshold values can be specified, whereby, for example, a first acceleration threshold value is smaller than a second acceleration threshold value, whereby only a warning message is generated when the first acceleration threshold value is exceeded and the high-voltage battery is deactivated when the second acceleration threshold value is exceeded. The acceleration sensor can preferably be designed to measure the acceleration in all spatial directions (x, y and z) or three individual acceleration sensors can be provided, with each of these acceleration sensors determining the acceleration in one spatial direction. This further development has the advantage that a more precise statement can be made about the deformation and/or displacement of the cell module.
Vorzugsweise ist vorgesehen, dass das Steuersignal dazu konfiguriert ist, die Hochvoltbatterie zu deaktivieren und/oder mittels des Steuersignals eine Warnmeldung bereitzustellen. Das heißt, dass die Hochvoltbatterie mittels des Steuersignals stillgelegt werden kann, indem elektrische Kontakte getrennt werden. Alternativ oder zusätzlich kann durch das Steuersignal auch eine Warneinrichtung des Kraftfahrzeugs angesteuert werden zur Ausgabe einer Warnmeldung. In einer alternativen Weiterbildung kann auch vorgesehen sein, dass ein definierter Kurzschluss bei Verformung einer der Batteriezellen erzeugt wird, durch den die Batterie stillgelegt wird und/oder einer oder mehrere Balancing-Kontakte können mittels einer definierten Sollbruchstelle bei einer zu starken Verformung und/oder Verschiebung getrennt werden, wodurch die Batterie stillgelegt beziehungsweise deaktiviert wird. Preferably, the control signal is configured to deactivate the high-voltage battery and/or to provide a warning message using the control signal. This means that the high-voltage battery can be shut down using the control signal by separating electrical contacts. Alternatively or additionally, the control signal can also control a warning device in the motor vehicle to issue a warning message. In an alternative development, it can also be provided that a defined short circuit is generated when one of the battery cells is deformed, which shuts down the battery, and/or one or more balancing contacts can be separated using a defined predetermined breaking point in the event of excessive deformation and/or displacement, which shuts down or deactivates the battery.
Ein weiterer Aspekt der Erfindung betrifft ein Verfahren zum Ermitteln einer Deformation von Batteriezellen in einer Hochvoltbatterie, umfassend die zuvor genannte Hochvoltbatterie, wobei bei einer Verformung und/oder Verschiebung von zumindest einer der mehreren Batteriezellen der Hochvoltbatterie in eine beliebige Raumrichtung die Sensoreinrichtung diese Verformung und/oder Verschiebung in die jeweilige Raumrichtung erfasst, wobei daraufhin ein Steuersignal erzeugt wird, mit dem eine Warneinrichtung eines Kraftfahrzeugs und/oder die Hochvoltbatterie zum Deaktivieren der Hochvoltbatterie angesteuert wird. Hierbei ergeben sich gleiche Vorteile und Variationsmöglichkeiten wie bei der Hochvoltbatterie. Für Anwendungsfälle oder Anwendungssituationen, die sich bei dem Verfahren ergeben können und die hier nicht explizit beschrieben sind, kann vorgesehen sein, dass gemäß dem Verfahren eine Fehlermeldung und/oder eine Aufforderung zur Eingabe einer Nutzerrückmeldung ausgegeben und/oder eine Standardeinstellung und/oder ein vorbestimmter Initialzustand eingestellt wird. A further aspect of the invention relates to a method for determining a deformation of battery cells in a high-voltage battery, comprising the aforementioned high-voltage battery, wherein in the event of a deformation and/or displacement of at least one of the plurality of battery cells of the high-voltage battery in any spatial direction, the sensor device detects this deformation and/or displacement in the respective spatial direction, whereby a control signal is then generated with which a warning device of a motor vehicle and/or the high-voltage battery is controlled to deactivate the high-voltage battery. This results in the same advantages and possible variations as with the high-voltage battery. For applications or application situations that may arise with the method and which are not explicitly described here, it can be provided that an error message and/or a request to input of user feedback and/or setting of a default setting and/or a predetermined initial state.
Erfindungsgemäß ist auch ein Kraftfahrzeug mit einer zuvor genannten Hochvoltbatterie bereitgestellt. Das erfindungsgemäße Kraftfahrzeug ist bevorzugt als Kraftwagen, insbesondere als Personenkraftwagen oder Lastkraftwagen, oder als Personenbus oder Motorrad ausgestaltet. Des Weiteren kann das Prinzip der Hochvoltbatterie auf andere Anwendungen übertragen werden, beispielsweise für Batterien in Smartphones oder Speicher für Solaranlagen. According to the invention, a motor vehicle with a high-voltage battery mentioned above is also provided. The motor vehicle according to the invention is preferably designed as a motor vehicle, in particular as a passenger car or truck, or as a passenger bus or motorcycle. Furthermore, the principle of the high-voltage battery can be transferred to other applications, for example for batteries in smartphones or storage devices for solar systems.
Zu der Erfindung gehört auch die Steuervorrichtung für das Kraftfahrzeug. Die Steuervorrichtung kann eine Datenverarbeitungsvorrichtung oder eine Prozessoreinrichtung aufweisen, die dazu eingerichtet ist, eine Ausführungsform des erfindungsgemäßen Verfahrens durchzuführen. Die Prozessoreinrichtung kann hierzu zumindest einen Mikroprozessor und/oder zumindest einen Mikrocontroller und/oder zumindest einen FPGA (Field Programmable Gate Array) und/oder zumindest einen DSP (Digital Signal Processor) aufweisen. Des Weiteren kann die Prozessoreinrichtung Programmcode aufweisen, der dazu eingerichtet ist, bei Ausführen durch die Prozessoreinrichtung die Ausführungsform des erfindungsgemäßen Verfahrens durchzuführen. Der Programmcode kann in einem Datenspeicher der Prozessoreinrichtung gespeichert sein. Eine Prozessorschaltung der Prozessoreinrichtung kann z. B. zumindest eine Schaltungsplatine und/oder zumindest ein SoC (System on Chip) aufweisen. The invention also includes the control device for the motor vehicle. The control device can have a data processing device or a processor device that is set up to carry out an embodiment of the method according to the invention. For this purpose, the processor device can have at least one microprocessor and/or at least one microcontroller and/or at least one FPGA (Field Programmable Gate Array) and/or at least one DSP (Digital Signal Processor). Furthermore, the processor device can have program code that is set up to carry out the embodiment of the method according to the invention when executed by the processor device. The program code can be stored in a data memory of the processor device. A processor circuit of the processor device can, for example, have at least one circuit board and/or at least one SoC (System on Chip).
Zu der Erfindung gehören auch Weiterbildungen des erfindungsgemäßen Verfahrens, die Merkmale aufweisen, wie sie bereits im Zusammenhang mit den Weiterbildungen der erfindungsgemäßen Hochvoltbatterie beschrieben worden sind. Aus diesem Grund sind die entsprechenden Weiterbildungen des erfindungsgemäßen Verfahrens hier nicht noch einmal beschrieben. Als eine weitere Lösung umfasst die Erfindung auch ein computerlesbares Speichermedium, umfassend Befehle, die bei der Ausführung durch einen Computer oder einen Computerverbund diesen veranlassen, eine Ausführungsform des erfindungsgemäßen Verfahrens auszuführen. Das Speichermedium kann z. B. zumindest teilweise als ein nicht-flüchtiger Datenspeicher (z. B. als eine Flash-Speicher und/oder als SSD - solid state drive) und/oder zumindest teilweise als ein flüchtiger Datenspeicher (z. B. als ein RAM - random access memory) ausgestaltet sein. Das Speichermedium kann aber auch beispielsweise als sogenannter Appstore-Server im Internet betrieben sein. Durch den Computer oder Computerverbund kann eine Prozessorschaltung mit zumindest einem Mikroprozessor bereitgestellt sein. Die Befehle können als Binärcode oder Assembler und/oder als Quellcode einer Programmiersprache (z. B. C) bereitgestellt sein. The invention also includes further developments of the method according to the invention which have features as have already been described in connection with the further developments of the high-voltage battery according to the invention. For this reason, the corresponding further developments of the method according to the invention are not described again here. As a further solution, the invention also includes a computer-readable storage medium, comprising instructions which, when executed by a computer or a computer network, cause it to carry out an embodiment of the method according to the invention. The storage medium can, for example, be designed at least partially as a non-volatile data memory (e.g. as a flash memory and/or as an SSD - solid state drive) and/or at least partially as a volatile data memory (e.g. as a RAM - random access memory). The storage medium can also, for example, be operated as a so-called app store server on the Internet. The computer or computer network can provide a processor circuit with at least one microprocessor. The instructions can be provided as binary code or assembler and/or as source code of a programming language (e.g. C).
Die Erfindung umfasst auch die Kombinationen der Merkmale der beschriebenen Ausführungsformen. Die Erfindung umfasst also auch Realisierungen, die jeweils eine Kombination der Merkmale mehrerer der beschriebenen Ausführungsformen aufweisen, sofern die Ausführungsformen nicht als sich gegenseitig ausschließend beschrieben wurden. The invention also includes combinations of the features of the described embodiments. The invention therefore also includes implementations that each have a combination of the features of several of the described embodiments, provided that the embodiments have not been described as mutually exclusive.
Im Folgenden sind Ausführungsbeispiele der Erfindung beschrieben. Hierzu zeigt: Exemplary embodiments of the invention are described below.
Fig. 1 eine schematische Seitenansicht einer Hochvoltbatterie in einem Kraftfahrzeug gemäß einer beispielhaften Ausführungsform; Fig. 1 is a schematic side view of a high-voltage battery in a motor vehicle according to an exemplary embodiment;
Fig. 2 eine schematische Draufsicht auf ein Zellmodul der Hochvoltbatterie; Fig. 2 is a schematic plan view of a cell module of the high-voltage battery;
Fig. 3 ein Zellmodul der Hochvoltbatterie in einer beispielhaften Situation; Fig. 4 ein Zellmodul der Hochvoltbatterie in einer weiteren beispielhaften Situation. Fig. 3 a cell module of the high-voltage battery in an exemplary situation; Fig. 4 a cell module of the high-voltage battery in another exemplary situation.
Bei den im Folgenden erläuterten Ausführungsbeispielen handelt es sich um bevorzugte Ausführungsformen der Erfindung. Bei den Ausführungsbeispielen stellen die beschriebenen Komponenten der Ausführungsformen jeweils einzelne, unabhängig voneinander zu betrachtende Merkmale der Erfindung dar, welche die Erfindung jeweils auch unabhängig voneinander weiterbilden. Daher soll die Offenbarung auch andere als die dargestellten Kombinationen der Merkmale der Ausführungsformen umfassen. Des Weiteren sind die beschriebenen Ausführungsformen auch durch weitere der bereits beschriebenen Merkmale der Erfindung ergänzbar. The exemplary embodiments explained below are preferred embodiments of the invention. In the exemplary embodiments, the components of the embodiments described each represent individual features of the invention that are to be considered independently of one another and which also develop the invention independently of one another. Therefore, the disclosure should also include combinations of the features of the embodiments other than those shown. Furthermore, the described embodiments can also be supplemented by other features of the invention already described.
In den Figuren bezeichnen gleiche Bezugszeichen jeweils funktionsgleiche Elemente. In the figures, identical reference symbols designate functionally identical elements.
In Fig. 1 ist ein stark schematisiertes Kraftfahrzeug 10 mit einer schematischen Seitenansicht einer Hochvoltbatterie 12 dargestellt. Die Hochvoltbatterie 12, die als Traktionsbatterie des Kraftfahrzeugs 10 ausgebildet sein kann, umfasst mehrere Batteriezellen 16, die zu einem Zellmodul 13 zusammengefasst sein können, vorzugsweise hintereinander gestapelt. Das Zellmodul 13 kann seitliche Endplatten 15, insbesondere mit einer Modulverschraubung 17, aufweisen und nach oben hin einen Busbarträger 14, der die Batteriezellen 16 elektrisch miteinander verbindet. Des Weiteren kann das Zellmodul 13 weitere Gehäuseelemente aufweisen, die hier nicht explizit gezeigt sind. Die Hochvoltbatterie 12 kann auch weitere Zellmodule 13 umfassen, die in dieser Fig. aus Übersichtlichkeitsgründen ebenfalls nicht dargestellt sind. Fig. 1 shows a highly schematic motor vehicle 10 with a schematic side view of a high-voltage battery 12. The high-voltage battery 12, which can be designed as a traction battery of the motor vehicle 10, comprises several battery cells 16, which can be combined to form a cell module 13, preferably stacked one behind the other. The cell module 13 can have lateral end plates 15, in particular with a module screw connection 17, and a busbar carrier 14 at the top, which electrically connects the battery cells 16 to one another. Furthermore, the cell module 13 can have further housing elements that are not explicitly shown here. The high-voltage battery 12 can also comprise further cell modules 13, which are also not shown in this figure for reasons of clarity.
Zur Erkennung einer Beschädigung des Zellmoduls 13 beziehungsweise der Batteriezellen 16 kann eine Sensoreinrichtung 18 bereitgestellt sein, die dazu ausgebildet ist, eine Verformung und/oder Verschiebung der Batteriezellen 16 zu erkennen. Dazu kann die Sensoreinrichtung 18 beispielsweise auf Höhe der mittleren Batteriezelle 16 im Busbarträger 14 beziehungsweise einem Gehäuse des Zellmoduls 13 angeordnet sein. Alternativ können auch mehrere Sensoreinrichtungen 18 bereitgestellt sein (in dieser Fig. nicht gezeigt), insbesondere für jede Batteriezelle 16 eine, wobei die mehreren Sensoreinrichtungen 18 beispielsweise im Busbarträger 14 über der jeweiligen Batteriezelle 16 und/oder an Seitenwänden beziehungsweise den Endplatten 15 bereitgestellt sein können. To detect damage to the cell module 13 or the battery cells 16, a sensor device 18 can be provided which is designed to detect deformation and/or displacement of the battery cells 16. For this purpose, the sensor device 18 can be mounted, for example, on Height of the middle battery cell 16 in the busbar carrier 14 or a housing of the cell module 13. Alternatively, several sensor devices 18 can be provided (not shown in this figure), in particular one for each battery cell 16, wherein the several sensor devices 18 can be provided for example in the busbar carrier 14 above the respective battery cell 16 and/or on side walls or the end plates 15.
Die Sensoreinrichtung 18 kann dazu ausgebildet sein, eine Verformung und/oder Verschiebung der jeweiligen Batteriezelle 16 in jede Raumrichtung zu erfassen. Dazu kann in einer Ausführungsform die Sensoreinrichtung 18 beispielsweise als berührungsloser Sensor, insbesondere induktiver Sensor ausgebildet sein, wobei die Sensoreinrichtung 18 dazu beispielsweise Induktionsspulen 20 (in dieser Fig. nicht gezeigt) aufweisen kann. Vorzugsweise kann auch ein zu den Induktionsspulen 20 korrespondierendes Flächenelement 19 auf der jeweiligen Batteriezelle 16 bereitgestellt sein, das beispielsweise als Metallplättchen ausgebildet ist. Wird das Flächenelement 19 in Relation zu den Induktionsspulen der Sensoreinrichtung 18 verschoben entsteht ein Stromsignal, das charakteristisch für die Verschiebungsrichtung ist. Alternativ kann die Sensoreinrichtung 18 als kapazitiver Sensor, optischer Sensor oder als Kontaktsensor ausgebildet sein, der mit der Batteriezelle 16 in Kontakt steht und eine Relativbewegung der Batteriezelle zu dem Gehäuse beziehungsweise dem Busbarträger 14 erfassen kann. Wird durch die Sensoreinrichtung 18 eine solche Verschiebung festgestellt, kann ein Steuersignal bereitgestellt werden. The sensor device 18 can be designed to detect a deformation and/or displacement of the respective battery cell 16 in any spatial direction. In one embodiment, the sensor device 18 can be designed, for example, as a contactless sensor, in particular an inductive sensor, wherein the sensor device 18 can have, for example, induction coils 20 (not shown in this figure). Preferably, a surface element 19 corresponding to the induction coils 20 can also be provided on the respective battery cell 16, which is designed, for example, as a metal plate. If the surface element 19 is displaced in relation to the induction coils of the sensor device 18, a current signal is generated that is characteristic of the direction of displacement. Alternatively, the sensor device 18 can be designed as a capacitive sensor, optical sensor or as a contact sensor that is in contact with the battery cell 16 and can detect a relative movement of the battery cell to the housing or the busbar carrier 14. If such a displacement is detected by the sensor device 18, a control signal can be provided.
Mittels des Steuersignals kann insbesondere eine Warneinrichtung (nicht gezeigt) des Kraftfahrzeugs 10, angesteuert werden, beispielsweise ein Bildschirm, durch den eine Beschädigung des Zellmoduls 13 angezeigt werden kann. Alternativ oder zusätzlich kann mittels des Steuersignals auch die Hochvoltbatterie 12 und/oder das Zellmodul 13 deaktiviert werden, indem beispielsweise Kontakte der Hochvoltbatterie 12 und/oder des Zellmoduls 13 mittels elektrisch gesteuerter Schalter gelöst werden. Besonders bevorzugt kann die Sensoreinrichtung 18 auch dazu ausgebildet sein, eine Wegstrecke der Verschiebung der Batteriezelle zu ermitteln. Das bedeutet, dass durch die Sensoreinrichtung 18 bestimmt werden kann, wie weit sich die Batteriezelle 16 im Vergleich zu einer ursprünglichen Position verschoben hat. Somit kann eine verbesserte Aussage über die Art der Beschädigung und/oder Verformung getroffen werden. The control signal can be used to control a warning device (not shown) of the motor vehicle 10, for example a screen that can indicate damage to the cell module 13. Alternatively or additionally, the high-voltage battery 12 and/or the cell module 13 can also be deactivated by means of the control signal, for example by releasing contacts of the high-voltage battery 12 and/or the cell module 13 by means of electrically controlled switches. Particularly preferred the sensor device 18 can also be designed to determine a distance of displacement of the battery cell. This means that the sensor device 18 can determine how far the battery cell 16 has shifted compared to an original position. This allows an improved statement to be made about the type of damage and/or deformation.
Besonders bevorzugt kann das Zellmodul 13 auch zumindest einen Beschleunigungssensor 22 aufweisen, der einen Beschleunigungswert messen kann. Somit kann, falls die Sensoreinrichtung 18 eine Verschiebung erkennt, die dazugehörigen Beschleunigungskräfte bestimmt werden, wobei damit festgestellt werden kann, ob die Beschleunigung über einem vorgegebenen Beschleunigungsschwellenwert liegt beziehungsweise welchen Wert die Beschleunigung aufweist. Somit kann verbessert auf einen möglichen Schaden des Zellmoduls 13 zurückgeschlossen werden. Particularly preferably, the cell module 13 can also have at least one acceleration sensor 22 that can measure an acceleration value. Thus, if the sensor device 18 detects a displacement, the associated acceleration forces can be determined, whereby it can be determined whether the acceleration is above a predetermined acceleration threshold value or what value the acceleration has. This makes it easier to draw conclusions about possible damage to the cell module 13.
In Fig. 2 ist eine schematische Draufsicht auf das Zellmodul 13 der Hochvoltbatterie 12 dargestellt. Hierbei ist der Busbarträger 14 zu sehen, der Busbars/Zellverbinder 24 umfasst. Des Weiteren sind die Induktionsspulen 20 der als induktiven Sensor ausgebildeten Sensoreinrichtung 18 dargestellt, wobei sich das Flächenelement 19, das an der mittleren Batteriezelle 16 angeordnet ist, in einem unbeschädigten Zustand des Zellmoduls 13 mittig zwischen den Induktionsspulen 20 befinden kann. Fig. 2 shows a schematic top view of the cell module 13 of the high-voltage battery 12. The busbar carrier 14 can be seen here, which includes busbars/cell connectors 24. Furthermore, the induction coils 20 of the sensor device 18 designed as an inductive sensor are shown, wherein the surface element 19, which is arranged on the middle battery cell 16, can be located centrally between the induction coils 20 when the cell module 13 is undamaged.
In Fig. 3 ist das Zellmodul 13 der Hochvoltbatterie 12 in einer beispielhaften Situation dargestellt, bei der aufgrund eines Alterungsprozesses zumindest eine Batteriezelle 16 eine starke Volumenausdehnung erfahren hat, dem so genannten Swelling. Hierbei ist in der oberen Hälfte der Fig. 3 die schematische Seitenansicht gezeigt und in der unteren Hälfte die schematische Draufsicht. Aufgrund der Volumenausdehnung von zumindest einer der Batteriezellen 16 können sich alle Batteriezellen 16 in dem Zellmodul 13 verschieben, wobei insbesondere die Endplatten 15 dabei nach außen gedrückt werden können. Vorzugsweise kann auch vorgesehen sein, dass der Busbarträger 14 nur an einer Seite mit einer der Endplatten 15 verbunden ist, wie hier beispielsweise auf der linken Seite dargestellt. Somit findet eine Verschiebung der Batteriezellen 16 hauptsächlich zur rechten Seite statt, an der die Endplatte 15 herausgedrückt wird. In Fig. 3, the cell module 13 of the high-voltage battery 12 is shown in an exemplary situation in which at least one battery cell 16 has experienced a strong volume expansion due to an aging process, the so-called swelling. The schematic side view is shown in the upper half of Fig. 3 and the schematic top view in the lower half. Due to the volume expansion of at least one of the battery cells 16, all battery cells 16 in the cell module 13 can shift, whereby in particular the end plates 15 can be pushed outwards. Preferably, it can also be provided that the busbar carrier 14 is only connected to one of the end plates 15 on one side. is connected, as shown here for example on the left side. Thus, a displacement of the battery cells 16 takes place mainly to the right side, where the end plate 15 is pressed out.
Durch die Verschiebung der Batteriezellen 16 aufgrund der Verformung kann das Flächenelement 19 in die Ausdehnungsrichtung bewegt werden, wodurch sich ein Signal, das von den Induktionsspulen 20 der Sensoreinrichtung 18 gemessen wird, entsprechend verändert. Aufgrund der Veränderung des durch die Induktionsspulen 20 gemessenen Signals kann die Sensoreinrichtung 18 die Verformung und/oder Verschiebung erkennen und ein Steuersignal erzeugen, mit dem die Hochvoltbatterie 12 angesteuert werden kann, insbesondere zur Deaktivierung. Alternativ oder zusätzlich kann eine Warneinrichtung (nicht gezeigt) des Kraftfahrzeugs 10 mit dem Steuersignal angesteuert werden, um eine Warnmeldung auszugeben. Somit kann also festgestellt werden, dass zumindest das Zellmoduls 13 aufgrund eines Alterungsprozesses ausgetauscht werden muss, ohne vorher die Hochvoltbatterie 12 öffnen zu müssen. Due to the displacement of the battery cells 16 due to the deformation, the surface element 19 can be moved in the direction of expansion, whereby a signal measured by the induction coils 20 of the sensor device 18 changes accordingly. Due to the change in the signal measured by the induction coils 20, the sensor device 18 can detect the deformation and/or displacement and generate a control signal with which the high-voltage battery 12 can be controlled, in particular for deactivation. Alternatively or additionally, a warning device (not shown) of the motor vehicle 10 can be controlled with the control signal in order to issue a warning message. It can therefore be determined that at least the cell module 13 must be replaced due to an aging process without first having to open the high-voltage battery 12.
Besonders bevorzugt kann, falls ein Beschleunigungssensor 22 für das Zellmodul 13 bereitgestellt ist, festgestellt werden, dass beim Swelling keine großen Beschleunigungen auf das Zellmodul 13 aufgetreten sind, wodurch zurückgeschlossen werden kann, dass die Sensoreinrichtung 18 aufgrund eines Alterungsprozesses von einer der Batteriezellen 16 und nicht aufgrund eines Stoßes beziehungsweise Impulses ausgelöst worden ist. Particularly preferably, if an acceleration sensor 22 is provided for the cell module 13, it can be determined that no large accelerations occurred on the cell module 13 during swelling, whereby it can be concluded that the sensor device 18 was triggered due to an aging process of one of the battery cells 16 and not due to an impact or impulse.
In Fig. 4 ist das Zellmodul 13 der Hochvoltbatterie 12 in einer weiteren beispielhaften Situation dargestellt, wobei in der oberen Hälfte wieder die schematische Seitenansicht gezeigt ist und in der unteren Hälfte die schematische Draufsicht. In dieser Situation kann ein Unfall des Kraftfahrzeugs 10 vorliegen, wodurch hohe Kräfte auf die Hochvoltbatterie 12 und damit auf die Batteriezellen 16 des Zellmoduls 13 wirken können, was beispielsweise zu einer Verschiebung von Batteriezellen 16 führen kann. In diesem Beispiel kann die mittlere Batteriezelle 16 aus dem Zellmodul 13 herausgeschoben werden, da auf dieses üblicherweise die größten Kräfte wirken. In Fig. 4, the cell module 13 of the high-voltage battery 12 is shown in another exemplary situation, with the schematic side view again being shown in the upper half and the schematic top view in the lower half. In this situation, an accident of the motor vehicle 10 may occur, whereby high forces can act on the high-voltage battery 12 and thus on the battery cells 16 of the cell module 13, which can lead, for example, to a displacement of battery cells 16. In this example, the middle battery cell 16 can be removed from the cell module 13. pushed out, as this is usually subject to the greatest forces.
Diese Verschiebung der Batteriezelle 16 kann durch die Sensoreinrichtung 18 erfasst werden, da sich die Batteriezelle 16, insbesondere das Flächenelement 19, relativ zu der Sensoreinrichtung 18, insbesondere in Richtung von einer der Induktionsspulen 20, verschiebt. Somit kann die Sensoreinrichtung 18 die seitliche Verschiebung der Batteriezelle 16 erkennen und das Steuersignal zur Deaktivierung der Hochvoltbatterie 12 und/oder zur Ausgabe einer Warnmeldung erzeugen. This displacement of the battery cell 16 can be detected by the sensor device 18, since the battery cell 16, in particular the surface element 19, is displaced relative to the sensor device 18, in particular in the direction of one of the induction coils 20. The sensor device 18 can thus detect the lateral displacement of the battery cell 16 and generate the control signal for deactivating the high-voltage battery 12 and/or for issuing a warning message.
Zusätzlich zu der Feststellung dieser Verschiebung der Batteriezelle 16 kann durch den Beschleunigungssensor 22 ein Beschleunigungswert erfasst werden, also eine Kraft, die auf das Zellmodul 13 während der Verschiebung gewirkt hat. In Abhängigkeit des Beschleunigungswerts kann dann beispielsweise entschieden werden, ob nur ein Warnsignal ausgegeben wird, oder ob die Hochvoltbatterie 12 deaktiviert werden muss, insbesondere wenn der Beschleunigungswert über einem Beschleunigungsschwellenwert liegt. In addition to detecting this displacement of the battery cell 16, the acceleration sensor 22 can detect an acceleration value, i.e. a force that acted on the cell module 13 during the displacement. Depending on the acceleration value, a decision can then be made, for example, as to whether only a warning signal is issued or whether the high-voltage battery 12 must be deactivated, in particular if the acceleration value is above an acceleration threshold value.
Insgesamt zeigen die Beispiele, wie durch die Erfindung ein Zellmodulsicherheitssensor bereitgestellt werden kann, durch den sowohl ein Alterungsprozess als auch Deformationen aufgrund von Unfällen erkannt werden können, ohne die Batterie 12 zu öffnen. Overall, the examples show how the invention can provide a cell module safety sensor that can detect both an aging process and deformations due to accidents without opening the battery 12.

Claims

PATENTANSPRÜCHE: PATENT CLAIMS:
1 . Hochvoltbatterie (12) für ein Kraftfahrzeug (10), umfassend eine Mehrzahl von Batteriezellen (16), die in zumindest einem Zellmodul (13), das ein Gehäuse (14, 15) aufweist, angeordnet sind, und zumindest eine Sensoreinrichtung (18), wobei die Sensoreinrichtung (18) dazu ausgebildet ist, eine mechanische Verformung und/oder Verschiebung von zumindest einer der Batteriezellen (16) in jede Raumrichtung zu erfassen und bei Erfassen der Verformung und/oder Verschiebung ein Steuersignal bereitzustellen. 1. High-voltage battery (12) for a motor vehicle (10), comprising a plurality of battery cells (16) arranged in at least one cell module (13) having a housing (14, 15), and at least one sensor device (18), wherein the sensor device (18) is designed to detect a mechanical deformation and/or displacement of at least one of the battery cells (16) in any spatial direction and to provide a control signal upon detection of the deformation and/or displacement.
2. Hochvoltbatterie (12) nach Anspruch 1 , wobei mindestens eine Sensoreinrichtung (18) für jede Batteriezelle (16) bereitgestellt ist. 2. High-voltage battery (12) according to claim 1, wherein at least one sensor device (18) is provided for each battery cell (16).
3. Hochvoltbatterie (12) nach Anspruch 1 , wobei genau eine Sensoreinrichtung (18) mittig an einer Oberseite des Gehäuses (14) angeordnet ist. 3. High-voltage battery (12) according to claim 1, wherein exactly one sensor device (18) is arranged centrally on an upper side of the housing (14).
4. Hochvoltbatterie (12) nach einem der vorhergehenden Ansprüche, wobei die jeweilige Sensoreinrichtung (18) einen Kontaktsensor aufweist. 4. High-voltage battery (12) according to one of the preceding claims, wherein the respective sensor device (18) has a contact sensor.
5. Hochvoltbatterie (12) nach einem der Ansprüche 1 bis 3, wobei die jeweilige Sensoreinrichtung (18) einen optischen Sensor und/oder einen kapazitiven Sensor und/oder einen induktiven Sensor (20) aufweist. 5. High-voltage battery (12) according to one of claims 1 to 3, wherein the respective sensor device (18) has an optical sensor and/or a capacitive sensor and/or an inductive sensor (20).
6. Hochvoltbatterie (12) nach einem der vorhergehenden Ansprüche, wobei die jeweilige Sensoreinrichtung (18) dazu ausgebildet ist, eine Wegstrecke der Verformung und/oder Verschiebung zu bestimmen. 6. High-voltage battery (12) according to one of the preceding claims, wherein the respective sensor device (18) is designed to determine a distance of the deformation and/or displacement.
7. Hochvoltbatterie (12) nach einem der vorhergehenden Ansprüche, wobei das Zellmodul (13) einen Beschleunigungssensor (22) aufweist, der dazu ausgebildet ist, bei Erkennen der Verformung und/oder Verschiebung der Batteriezellen (16) mittels der Sensoreinrichtung (18) zusätzlich einen dabei auftretenden Beschleunigungswert auf das Zellmodul (13) bereitzustellen. Hochvoltbatterie (12) nach einem der vorhergehenden Ansprüche, wobei das Steuersignal dazu konfiguriert ist, die Hochvoltbatterie (12) zu deaktivieren und/oder eine Warnmeldung bereitzustellen. Verfahren zum Ermitteln einer Deformation von Batteriezellen (16) in einer Hochvoltbatterie (12), umfassend die Hochvoltbatterie (12) nach einem der vorhergehenden Ansprüche, wobei bei einer Verformung und/oder Verschiebung von zumindest einer der mehreren Batteriezellen (16) in eine beliebige Raumrichtung die Sensoreinrichtung (18) diese Verformung und/oder Verschiebung in die jeweilige Raumrichtung erfasst, wobei daraufhin ein Steuersignal erzeugt wird, mit dem eine Warneinrichtung eines Kraftfahrzeugs (10) und/oder die Hochvoltbatterie (12) zum Deaktivieren der Hochvoltbatterie (12) angesteuert wird. Kraftfahrzeug (10) mit einer Hochvoltbatterie (12) nach einem der Ansprüche 1 bis 9. 7. High-voltage battery (12) according to one of the preceding claims, wherein the cell module (13) has an acceleration sensor (22) which is designed to detect the deformation and/or Displacement of the battery cells (16) by means of the sensor device (18) additionally provides an acceleration value that occurs to the cell module (13). High-voltage battery (12) according to one of the preceding claims, wherein the control signal is configured to deactivate the high-voltage battery (12) and/or to provide a warning message. Method for determining a deformation of battery cells (16) in a high-voltage battery (12), comprising the high-voltage battery (12) according to one of the preceding claims, wherein in the event of a deformation and/or displacement of at least one of the plurality of battery cells (16) in any spatial direction, the sensor device (18) detects this deformation and/or displacement in the respective spatial direction, whereupon a control signal is generated with which a warning device of a motor vehicle (10) and/or the high-voltage battery (12) is controlled to deactivate the high-voltage battery (12). Motor vehicle (10) with a high-voltage battery (12) according to one of claims 1 to 9.
PCT/EP2023/081722 2022-12-06 2023-11-14 High-voltage battery with a sensor unit for detecting a deformation and/or shifting of a battery cell, motor vehicle with a high-voltage battery and method for determining a deformation within a high-voltage battery WO2024120764A1 (en)

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