WO2020160765A1 - Unit to test and/or charge battery cells or battery modules for electrical vehicles - Google Patents

Unit to test and/or charge battery cells or battery modules for electrical vehicles Download PDF

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Publication number
WO2020160765A1
WO2020160765A1 PCT/EP2019/052907 EP2019052907W WO2020160765A1 WO 2020160765 A1 WO2020160765 A1 WO 2020160765A1 EP 2019052907 W EP2019052907 W EP 2019052907W WO 2020160765 A1 WO2020160765 A1 WO 2020160765A1
Authority
WO
WIPO (PCT)
Prior art keywords
unit
battery
interior
test
battery cells
Prior art date
Application number
PCT/EP2019/052907
Other languages
French (fr)
Inventor
Christian Benno HOELTING
Original Assignee
Abb Schweiz Ag
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 Abb Schweiz Ag filed Critical Abb Schweiz Ag
Priority to PCT/EP2019/052907 priority Critical patent/WO2020160765A1/en
Publication of WO2020160765A1 publication Critical patent/WO2020160765A1/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
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/572—Means for preventing undesired use or discharge
    • H01M50/574—Devices or arrangements for the interruption of current
    • 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
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R1/00—Details of instruments or arrangements of the types included in groups G01R5/00 - G01R13/00 and G01R31/00
    • G01R1/02—General constructional details
    • G01R1/04—Housings; Supporting members; Arrangements of terminals
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/36—Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
    • G01R31/3644—Constructional arrangements
    • 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
    • H01M10/4207—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells for several batteries or cells simultaneously or sequentially
    • 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
    • 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
    • H01M10/486—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for measuring temperature
    • 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
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/61—Types of temperature control
    • H01M10/613—Cooling or keeping cold
    • 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
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/62—Heating or cooling; Temperature control specially adapted for specific applications
    • H01M10/625—Vehicles
    • 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
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/658—Means for temperature control structurally associated with the cells by thermal insulation or shielding
    • 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
    • H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
    • H01M50/24—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries from their environment, e.g. from corrosion
    • 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
    • H01M10/44—Methods for charging or discharging
    • 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
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/656—Means for temperature control structurally associated with the cells characterised by the type of heat-exchange fluid
    • H01M10/6561—Gases
    • 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
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/656—Means for temperature control structurally associated with the cells characterised by the type of heat-exchange fluid
    • H01M10/6567—Liquids
    • 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
    • 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
    • H01M50/30—Arrangements for facilitating escape of gases
    • 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
    • H01M50/30—Arrangements for facilitating escape of gases
    • H01M50/342—Non-re-sealable arrangements
    • H01M50/3425—Non-re-sealable arrangements in the form of rupturable membranes or weakened parts, e.g. pierced with the aid of a sharp member
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the invention is related to a unit to test and/ or charge battery cells or battery mod ules for electrical vehicles.
  • a typical battery module for an electrical vehicle is composed of a number of battery cells.
  • a battery module may, as example and by no way meant to be restrictive, com prise 14 battery cells and have a size of 1700 x 1100 x 300 mm and a weight of 248 kg (547 lbs). Such a heavy battery module has to be handled with care.
  • Battery mod ules of this kind are assembled in a plant or a battery module assembly line, where the battery cells are assembled into a housing to result in a battery module.
  • Such assembly lines are highly automated and apply for example industrial robots for han dling the battery cells or battery modules in various states of the assembly process.
  • Battery cells and battery modules have to be tested, for example electrically charged and/or discharged in the plant or at the assembly line, wherein the battery modules run through several test- and charge-cycles.
  • a malfunction may occur if the battery cell or battery module exceeds defined pa rameters during the test- and charge-cycles. These parameters include especially temperature or voltage. But also a fire or an explosion may lead to malfunctions and may endanger operational staff of a plant. The parameters mentioned especially can lead to a self-ignition of a battery cell or battery module and thus become a significant security risk for humans and the plant and/ or the production area. The resulting personal injury and property damage abso lutely make necessary a critical assessment and weighing of the risks and also a de termination of suitable countermeasures. Further, a minimization of the downtime of the production and a reduction of risks, which occur during the production, are de sired.
  • the hazard potential is significantly higher as in another area.
  • the reason for this is the general hazard po tential of the cell modules used and their properties.
  • lithium compounds and their derivatives are used in battery cells or battery modules.
  • the battery cells or battery modules may be tested at two positions or two steps dur ing an assembly process. Firstly an inline testing of the battery cells may be done and secondly a testing of the assembled battery modules may be done.
  • the test of the assembled battery modules is typically done at the end of the assembly process, and thus it is called end-of-line testing, or EOL testing.
  • the object of the invention therefore is to develop a device, which prevents emer gencies when battery cells or battery modules are tested and/ or charged.
  • the unit mentioned above comprises a container, which hous es a test bench and/ or equipment to test and/ or charge battery cells or battery mod ules, wherein the unit comprises means to insert a battery cell or battery module, which shall be tested and/ or charged, into the interior of the unit and wherein the test bench and / or the equipment is/ are integrated at defined interface points in the inte rior of the unit and is/ are accessible via connection means.
  • such a unit acts as a Battery- Emergency-Prevention-Unit (BEPU). Temperature, voltage, fire and explosion may occur in such a self-contained unit. Insofar an intrinsically safe concept is given.
  • BEPU Battery- Emergency-Prevention-Unit
  • This concept is based on the fact, that the equipment to test and/ or charge is no longer located independently and non-intrinsically in a plant or in production line, but is located in a closed, encapsulated volume, namely within the container of the unit or within several containers or units.
  • One unit is based on the principle of handling battery cells or battery modules in a modular manner.
  • a battery cell or battery module is received in the container, where in inside the unit there are integrated at defined interface points a test bench and/ or equipment to test and/ or charge battery cells or battery modules.
  • the test bench and/ or the equipment is/ are accessible via connection means. Through this, per sonal staff can monitor or control the test bench and/ or the equipment to test and/ or charge from outside of the unit and are not endangered by malfunctions and their results, which occur within the unit.
  • the container encloses an inner container.
  • the unit is double-walled.
  • the unit comprises at least one panel, which is double- walled and/ or which is double-walled, wherein an insulating or fire protection materi al is sandwiched between the two walls of the panel.
  • a panel may be developed as a floor, a roof or a side wall of the unit. Through this, inside the unit there is a complete ly thermally insulated interior area.
  • the fire protection preferably fulfils requirements of F90 protection.
  • the insulating material preferably may comprise ALSIFLEX (Trade mark) or AEROGEL (Trade mark).
  • the unit comprises at least one door, which allows access to the interior of the unit.
  • the door also may be double-walled or double-walled, wherein an insulating or fire protection material, preferably as mentioned above, is sandwiched between two layers of the door.
  • the door allows an access to the interior of the unit.
  • Personal staff may walk into the unit or the container by passing the door.
  • the door comprises a fire protection material and/ or seals the interior of the unit in a gastight manner. Through this, inside the unit there is a completely thermally insulated interior area. Gas and hazardous material may not pass the door. Personal staff being besides or near the door are not endangered.
  • the unit comprises at least one rupture disc for pressure relief. If the pressure inside the unit exceeds a defined value, the rupture discs may be removed and create at least one channel to realize a pressure reduction within the unit.
  • Such channels and/ or the rupture discs may be connected to the outside of a building, es pecially may be connected to a wall and/ or a roof.
  • the unit comprises at least one air vent for fumigation.
  • Gas may leave the interior of the unit via the vents.
  • a continuous overflow of a gas may be lead through the air vents, when this gas is lead into the unit.
  • Exhaust air may leave the interior of the unit via the air vents.
  • the unit comprises at least one hose connection to lead water and/ or carbon dioxide or another gas into the interior of the unit.
  • hose connection is developed as a STORK coupling (2 1 ⁇ 2 x 89), so a fire brigade may use common hoses to connect them with the interior of the unit.
  • a continuous over flow of carbon dioxide may be lead through the air vents when this gas is lead into the unit via a hose connection.
  • the unit comprises at least one inspection window and/ or a porthole. Through this, personal staff can monitor the interior of the unit.
  • the unit comprises means to monitor electrical and thermal battery parameters.
  • personal staff, a controller or a computer system may pre- vent malfunctions.
  • the monitoring of the parameters may be done continuously.
  • Data concerning the parameters may be transmitted to a control system or to a controller or to the personal staff.
  • the unit comprises a fully automatic switch-off and/ or a fully automatic decontacting means of the entire power supply.
  • the unit comprises a means to create a fully automatic emergency signal, which is sent to a controller and/ or to the fire brigade of a plant. Through this, spreading of fire within a plant may be prevented.
  • the unit may be flooded by water or by a gas through the fire brigade.
  • the unit comprises a means to create a fully automatic evacuation alarm.
  • personal staff may seek shelter and may leave an emergency area.
  • the alarm may be optical and/ or acoustical.
  • the unit comprises means to cool the interior of the unit and/ or means to monitor the unit by a fire department or the fire brigade.
  • a fire department or the fire brigade may moni tor continuously the cooling of the interior of the unit.
  • a plant especially an assembly line for assembling battery modules from battery cells advantageously comprises at least one such unit.
  • Several units may be com bined to create an assembly area and/ or a testing and/ or charging area which is fully encapsulated within containers.
  • At least one unit is part of an assembly and/ or a testing and/ or a charging area and battery cells or battery modules are handled by at least one industrial robot.
  • the industrial robot may be used to automatically deliver the bat tery cells or battery modules to the interior of the unit and to automatically connect the battery cells or battery modules to the interface points at the test bench and/or equipment within the interior of the unit to test and/or charge battery cells or battery modules.
  • the industrial robot may also be used to automatically disconnect the bat tery cells or battery modules from the interface points at the test bench and/or equipment within the interior of the unit after testing is finished and to automatically extract the battery cells or battery modules out of the interior of the unit.
  • Industrial robots especially industrial robots having at least one hinged bracket with six or more axes, are able to handle heavy battery cells or battery modules in narrow spac es.
  • an industrial robot is located within a unit and transports a bat tery cell or battery module from one unit to another unit.
  • the unit described here is based on a modular cell concept.
  • a standardized unit namely a module for the modular cell concept
  • the test bench and the mentioned equipment are integrated with all necessary connections.
  • Such connections may be provided for electrical contact, for controlling measures and/ or for joining media.
  • connections with or to the unit preferably are designed as quick-release couplings and are disconnected fully automatically in case of emergency.
  • the back ground to the necessity of complete disconnection results from the core of the unit.
  • the unit can be completely flooded with different extinguishants and/ or coolants.
  • the primary feature of the unit namely the Battery-Emergency-Prevention-Unit is its fully encapsulated design.
  • Fig. 1 shows at the top a perspective view of a battery module composed of sev eral battery cells, which may be tested and/ or charged within a unit, and shows at the bottom an electrical vehicle, which houses such a battery module,
  • Fig. 2 shows a perspective view of a unit, namely a Battery-Emergency-
  • Prevention-Unit which comprises at least one container, which may re- ceive or house a battery cell or battery module
  • Fig. 3 shows a perspective view of the unit according to Fig. 2, wherein a door of this unit is opened, and
  • Fig. 4 shows schematically a plant, which comprises units according to Fig. 2 or
  • Fig. 1 shows at the top a perspective view of a battery module 1 comprising a num ber of battery cells within a module housing, which may be tested and/ or charged in a plant and/ or at an assembly line. Further, Fig. 1 shows at the bottom an electrical vehicle 2, which houses such a battery module 1 .
  • Fig. 2 shows a unit 3 to test and/ or charge battery cells or battery modules 1 for electrical vehicles 2.
  • the unit 3 comprises an outer container 4, which houses a test bench 19 and equipment 20 to test and/ or charge battery modules 1 .
  • the unit 3 comprises means 5 to insert a battery module 1 , which shall be tested and/ or charged, into the interior of the unit 3.
  • the means 5 also allow to extract the battery module 1 from the interior of the unit 3.
  • the means 5 to insert the battery module 1 is an insertion or extracting opening, which comprises a respective door configured to give free the opening for insertion or extraction of the battery cells or modules and to close the opening after insertion.
  • test bench 19 and the equipment 20, see figure 4 are integrated at defined inter face points 1 1 in the interior of the unit 3 and are accessible via connection means 6.
  • connection means 6 are electrically connected with the test bench 19 and the equipment 20, which are located at the interface points 1 1 .
  • the connection means 6 also may be connected with the test bench 19 and the equipment 20 via internet, ethernet or in a wireless mode, for example but not restricted to radio communica tion.
  • Fig. 3 shows, that the outer container 4 encloses an inner container 7. Further, the unit 3 comprises five panels which are double-walled, wherein an insulating or fire protection material is sandwiched between the two walls of each panel.
  • Fig. 3 shows, that the unit 3 comprises at least one door 8, which allows access to the interior of the unit 3.
  • the door 8 comprises a fire protection material and seals the interior of the unit 3 in a gastight manner.
  • the door 8 is double-walled.
  • Fig. 2 and Fig. 3 show, that the unit 3, namely at least the container 4, comprises two rupture discs 9 for pressure relief.
  • the unit 3 also comprises two air vents 10 for fu migation.
  • the container 4 comprises at least one hose connection 12 to lead water and/ or carbon dioxide or another gas into the interior of the unit 3.
  • the container 4 comprises at least one inspection window or a porthole 13.
  • the unit 3 comprises means 14 to monitor electrical and thermal battery parameters.
  • the unit 3 comprises a fully automatic switch-off, a fully automatic decontacting means of the entire power supply and a means to create a fully automatic emergency signal, which is sent to a controller 15 and the fire brigade of a plant. Further the unit 3 comprises a means to create a fully automatic evacuation alarm.
  • the unit 3 com prises means 16 to cool the interior of the unit 3 and means 14 to monitor the unit 3 by a fire department and/ or the fire brigade.
  • Fig. 4 schematically shows exemplarily a plant, comprising several units 3, wherein three units 3 are part of an encapsulated assembly and/ or testing and/ or charging area 17. It is understood that a plant or assembly line may also have only one such units 3, or may have single units 3 distributed at different location at the assembly line, or may have one or more assemblies of two units 3 arranged one upon the other for parallel testing of two battery cells or battery modules, one in each of the units 3 at a time, wherein the units 3 are not interconnected.
  • Battery modules 1 are handled by at least one industrial robot 18. They are delivered to the interior of a first unit 3 and may be extracted from the first unit 3 after testing by means of the robot 18. Also at least one industrial robot 18 may act within the interior of each further unit 3 and is then located within the interior of said unit 3. Through this, a battery cell or battery module can be transported from one unit 3 to another unit 3.
  • each unit 3 special test- and/ or charge-cycles may occur.
  • the battery module 1 can be transported within the units 3 in the direction of the arrows. Inside each unit 3 are a test bench 19 and equipment 20 to test and/ or charge the battery module 1 in an encapsulated environment.
  • the units 3 have docking means which allow to connect two units 3 in such a manner that their interior areas are connected.
  • a battery module 1 may be transported from one means 5 to insert to another means 5 to insert.
  • All data concerning the battery modules 1 may be transmitted via cables or wireless via internet or ethernet to a computer system, to the personal staff and/ or to the fire brigade of the plant.
  • the unit 3 preferably has a size, which allows access of at least one human person.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Battery Mounting, Suspending (AREA)

Abstract

A unit to test and/ or charge battery cells or battery modules (1) for electrical vehicles (2), characterized in that the unit (3) comprises a container (4), which houses a test bench (19) and/ or equipment (20) to test and/ or charge battery cells or battery modules (1), wherein the unit (3) comprises means (5) to insert a battery cell or battery module (1), which shall be tested and/ or charged, into the interior of the unit (3) and wherein the test bench (19) and/ or the equipment (20) is/ are integrated at defined interface points in the interior of the unit (3) and is/ are accessible via connection means (6), achieves the object, to develop a device which prevents emergencies when battery cells or battery modules or battery systems are tested and/ or charged.

Description

Unit to test and/ or charge battery cells or battery modules for electrical vehicles
Description
The invention is related to a unit to test and/ or charge battery cells or battery mod ules for electrical vehicles.
A typical battery module for an electrical vehicle is composed of a number of battery cells. A battery module may, as example and by no way meant to be restrictive, com prise 14 battery cells and have a size of 1700 x 1100 x 300 mm and a weight of 248 kg (547 lbs). Such a heavy battery module has to be handled with care. Battery mod ules of this kind are assembled in a plant or a battery module assembly line, where the battery cells are assembled into a housing to result in a battery module. Such assembly lines are highly automated and apply for example industrial robots for han dling the battery cells or battery modules in various states of the assembly process. Battery cells and battery modules have to be tested, for example electrically charged and/or discharged in the plant or at the assembly line, wherein the battery modules run through several test- and charge-cycles.
Due to the possible event of a malfunction, especially in the case of fire, during the test- and charge cycles, there is a need for a solution, which guarantees a reliable and secure handling of the battery cells or battery modules at several stations of the plant or the assembly line. Safety requirements for the handling of a battery cell or battery module necessarily have to be met in order to provide an emergency preven tion concept in case of fire in a series production.
A malfunction may occur if the battery cell or battery module exceeds defined pa rameters during the test- and charge-cycles. These parameters include especially temperature or voltage. But also a fire or an explosion may lead to malfunctions and may endanger operational staff of a plant. The parameters mentioned especially can lead to a self-ignition of a battery cell or battery module and thus become a significant security risk for humans and the plant and/ or the production area. The resulting personal injury and property damage abso lutely make necessary a critical assessment and weighing of the risks and also a de termination of suitable countermeasures. Further, a minimization of the downtime of the production and a reduction of risks, which occur during the production, are de sired.
In an area, where testing and charging equipment is located, the hazard potential is significantly higher as in another area. The reason for this is the general hazard po tential of the cell modules used and their properties. Typically, lithium compounds and their derivatives are used in battery cells or battery modules.
The battery cells or battery modules may be tested at two positions or two steps dur ing an assembly process. Firstly an inline testing of the battery cells may be done and secondly a testing of the assembled battery modules may be done. The test of the assembled battery modules is typically done at the end of the assembly process, and thus it is called end-of-line testing, or EOL testing.
Due to its physical properties a battery cell or battery module, that has caught fire, creates a risk, that is no longer controllable. This can lead to massive and unfore seeable damage. The resulting damage to systems, production facilities and last but not least the resulting loss of production and loss of production costs force to adopt a correspondingly damage-reducing concept.
The object of the invention therefore is to develop a device, which prevents emer gencies when battery cells or battery modules are tested and/ or charged.
The object of the invention is achieved by means of the features of claim 1.
According to this claim the unit mentioned above comprises a container, which hous es a test bench and/ or equipment to test and/ or charge battery cells or battery mod ules, wherein the unit comprises means to insert a battery cell or battery module, which shall be tested and/ or charged, into the interior of the unit and wherein the test bench and / or the equipment is/ are integrated at defined interface points in the inte rior of the unit and is/ are accessible via connection means.
According to the invention, it has been found that such a unit acts as a Battery- Emergency-Prevention-Unit (BEPU). Temperature, voltage, fire and explosion may occur in such a self-contained unit. Insofar an intrinsically safe concept is given.
This concept is based on the fact, that the equipment to test and/ or charge is no longer located independently and non-intrinsically in a plant or in production line, but is located in a closed, encapsulated volume, namely within the container of the unit or within several containers or units.
One unit is based on the principle of handling battery cells or battery modules in a modular manner. A battery cell or battery module is received in the container, where in inside the unit there are integrated at defined interface points a test bench and/ or equipment to test and/ or charge battery cells or battery modules. The test bench and/ or the equipment is/ are accessible via connection means. Through this, per sonal staff can monitor or control the test bench and/ or the equipment to test and/ or charge from outside of the unit and are not endangered by malfunctions and their results, which occur within the unit.
Advantageously, the container encloses an inner container. Through this, the unit is double-walled. Especially the floor, the roof and the side walls, but also a door, are double-walled.
Further advantageously, the unit comprises at least one panel, which is double- walled and/ or which is double-walled, wherein an insulating or fire protection materi al is sandwiched between the two walls of the panel. A panel may be developed as a floor, a roof or a side wall of the unit. Through this, inside the unit there is a complete ly thermally insulated interior area. The fire protection preferably fulfils requirements of F90 protection. The insulating material preferably may comprise ALSIFLEX (Trade mark) or AEROGEL (Trade mark).
Advantageously, the unit comprises at least one door, which allows access to the interior of the unit. The door also may be double-walled or double-walled, wherein an insulating or fire protection material, preferably as mentioned above, is sandwiched between two layers of the door. The door allows an access to the interior of the unit. Personal staff may walk into the unit or the container by passing the door.
Further advantageously, the door comprises a fire protection material and/ or seals the interior of the unit in a gastight manner. Through this, inside the unit there is a completely thermally insulated interior area. Gas and hazardous material may not pass the door. Personal staff being besides or near the door are not endangered.
Advantageously, the unit comprises at least one rupture disc for pressure relief. If the pressure inside the unit exceeds a defined value, the rupture discs may be removed and create at least one channel to realize a pressure reduction within the unit. Such channels and/ or the rupture discs may be connected to the outside of a building, es pecially may be connected to a wall and/ or a roof.
Further advantageously, the unit comprises at least one air vent for fumigation. Gas may leave the interior of the unit via the vents. A continuous overflow of a gas may be lead through the air vents, when this gas is lead into the unit. Exhaust air may leave the interior of the unit via the air vents.
Advantageously, the unit comprises at least one hose connection to lead water and/ or carbon dioxide or another gas into the interior of the unit. Through this, in the case of fire water or carbon dioxide may be lead into the interior of the unit. Especially the hose connection is developed as a STORK coupling (2 ½ x 89), so a fire brigade may use common hoses to connect them with the interior of the unit. A continuous over flow of carbon dioxide may be lead through the air vents when this gas is lead into the unit via a hose connection.
Further advantageously, the unit comprises at least one inspection window and/ or a porthole. Through this, personal staff can monitor the interior of the unit.
Advantageously, the unit comprises means to monitor electrical and thermal battery parameters. Through this, personal staff, a controller or a computer system may pre- vent malfunctions. The monitoring of the parameters may be done continuously. Data concerning the parameters may be transmitted to a control system or to a controller or to the personal staff.
Further advantageously, the unit comprises a fully automatic switch-off and/ or a fully automatic decontacting means of the entire power supply. Through this, in case of a malfunction damages of the test bench and/ or the equipment may be prevented. Es pecially spreading of damages is prevented. Further malfunctions may be prevented or reduced.
Advantageously, the unit comprises a means to create a fully automatic emergency signal, which is sent to a controller and/ or to the fire brigade of a plant. Through this, spreading of fire within a plant may be prevented. The unit may be flooded by water or by a gas through the fire brigade.
Further advantageously, the unit comprises a means to create a fully automatic evacuation alarm. Through this, personal staff may seek shelter and may leave an emergency area. The alarm may be optical and/ or acoustical.
Advantageously, the unit comprises means to cool the interior of the unit and/ or means to monitor the unit by a fire department or the fire brigade. Through this, mal functions may be prevented. It may be prevented that battery cells or battery mod ules become to hot and catch fire. The fire department or the fire brigade may moni tor continuously the cooling of the interior of the unit.
A plant, especially an assembly line for assembling battery modules from battery cells advantageously comprises at least one such unit. Several units may be com bined to create an assembly area and/ or a testing and/ or charging area which is fully encapsulated within containers.
Further advantageously, at least one unit is part of an assembly and/ or a testing and/ or a charging area and battery cells or battery modules are handled by at least one industrial robot. The industrial robot may be used to automatically deliver the bat tery cells or battery modules to the interior of the unit and to automatically connect the battery cells or battery modules to the interface points at the test bench and/or equipment within the interior of the unit to test and/or charge battery cells or battery modules. The industrial robot may also be used to automatically disconnect the bat tery cells or battery modules from the interface points at the test bench and/or equipment within the interior of the unit after testing is finished and to automatically extract the battery cells or battery modules out of the interior of the unit. Industrial robots, especially industrial robots having at least one hinged bracket with six or more axes, are able to handle heavy battery cells or battery modules in narrow spac es.
It is also possible that an industrial robot is located within a unit and transports a bat tery cell or battery module from one unit to another unit.
The unit described here is based on a modular cell concept. In a standardized unit, namely a module for the modular cell concept, the test bench and the mentioned equipment are integrated with all necessary connections. Such connections may be provided for electrical contact, for controlling measures and/ or for joining media.
Some or all connections with or to the unit preferably are designed as quick-release couplings and are disconnected fully automatically in case of emergency. The back ground to the necessity of complete disconnection results from the core of the unit.
The unit can be completely flooded with different extinguishants and/ or coolants.
The primary feature of the unit, namely the Battery-Emergency-Prevention-Unit is its fully encapsulated design.
In the drawings:
Fig. 1 shows at the top a perspective view of a battery module composed of sev eral battery cells, which may be tested and/ or charged within a unit, and shows at the bottom an electrical vehicle, which houses such a battery module,
Fig. 2 shows a perspective view of a unit, namely a Battery-Emergency-
Prevention-Unit, which comprises at least one container, which may re- ceive or house a battery cell or battery module
Fig. 3 shows a perspective view of the unit according to Fig. 2, wherein a door of this unit is opened, and
Fig. 4 shows schematically a plant, which comprises units according to Fig. 2 or
3, wherein the units build up an encapsulated testing and/ or charging ar ea.
Fig. 1 shows at the top a perspective view of a battery module 1 comprising a num ber of battery cells within a module housing, which may be tested and/ or charged in a plant and/ or at an assembly line. Further, Fig. 1 shows at the bottom an electrical vehicle 2, which houses such a battery module 1 .
Fig. 2 shows a unit 3 to test and/ or charge battery cells or battery modules 1 for electrical vehicles 2. The unit 3 comprises an outer container 4, which houses a test bench 19 and equipment 20 to test and/ or charge battery modules 1 .
The unit 3 comprises means 5 to insert a battery module 1 , which shall be tested and/ or charged, into the interior of the unit 3. The means 5 also allow to extract the battery module 1 from the interior of the unit 3. The means 5 to insert the battery module 1 is an insertion or extracting opening, which comprises a respective door configured to give free the opening for insertion or extraction of the battery cells or modules and to close the opening after insertion.
The test bench 19 and the equipment 20, see figure 4, are integrated at defined inter face points 1 1 in the interior of the unit 3 and are accessible via connection means 6.
The connection means 6 are electrically connected with the test bench 19 and the equipment 20, which are located at the interface points 1 1 . The connection means 6 also may be connected with the test bench 19 and the equipment 20 via internet, ethernet or in a wireless mode, for example but not restricted to radio communica tion. Fig. 3 shows, that the outer container 4 encloses an inner container 7. Further, the unit 3 comprises five panels which are double-walled, wherein an insulating or fire protection material is sandwiched between the two walls of each panel.
Fig. 3 shows, that the unit 3 comprises at least one door 8, which allows access to the interior of the unit 3. The door 8 comprises a fire protection material and seals the interior of the unit 3 in a gastight manner. The door 8 is double-walled.
Fig. 2 and Fig. 3 show, that the unit 3, namely at least the container 4, comprises two rupture discs 9 for pressure relief. The unit 3 also comprises two air vents 10 for fu migation. The container 4 comprises at least one hose connection 12 to lead water and/ or carbon dioxide or another gas into the interior of the unit 3. The container 4 comprises at least one inspection window or a porthole 13.
The unit 3 comprises means 14 to monitor electrical and thermal battery parameters. The unit 3 comprises a fully automatic switch-off, a fully automatic decontacting means of the entire power supply and a means to create a fully automatic emergency signal, which is sent to a controller 15 and the fire brigade of a plant. Further the unit 3 comprises a means to create a fully automatic evacuation alarm. The unit 3 com prises means 16 to cool the interior of the unit 3 and means 14 to monitor the unit 3 by a fire department and/ or the fire brigade.
Fig. 4 schematically shows exemplarily a plant, comprising several units 3, wherein three units 3 are part of an encapsulated assembly and/ or testing and/ or charging area 17. It is understood that a plant or assembly line may also have only one such units 3, or may have single units 3 distributed at different location at the assembly line, or may have one or more assemblies of two units 3 arranged one upon the other for parallel testing of two battery cells or battery modules, one in each of the units 3 at a time, wherein the units 3 are not interconnected.
Battery modules 1 are handled by at least one industrial robot 18. They are delivered to the interior of a first unit 3 and may be extracted from the first unit 3 after testing by means of the robot 18. Also at least one industrial robot 18 may act within the interior of each further unit 3 and is then located within the interior of said unit 3. Through this, a battery cell or battery module can be transported from one unit 3 to another unit 3.
In each unit 3 special test- and/ or charge-cycles may occur. The battery module 1 can be transported within the units 3 in the direction of the arrows. Inside each unit 3 are a test bench 19 and equipment 20 to test and/ or charge the battery module 1 in an encapsulated environment.
The units 3 have docking means which allow to connect two units 3 in such a manner that their interior areas are connected. A battery module 1 may be transported from one means 5 to insert to another means 5 to insert.
All data concerning the battery modules 1 , which are monitored within a unit 3, may be transmitted via cables or wireless via internet or ethernet to a computer system, to the personal staff and/ or to the fire brigade of the plant.
The unit 3 preferably has a size, which allows access of at least one human person.
Reference numbers
Figure imgf000011_0001

Claims

Claims
1. Unit to test and / or charge battery cells or battery cells or battery modules (1 ) for electrical vehicles (2),
characterized in that the unit (3) comprises a container (4), which houses a test bench (19) and/ or equipment (20) to test and/ or charge battery cells or battery modules (1 ), wherein the unit (3) comprises means (5) to insert a battery cell or battery module (1 ), which shall be tested and/ or charged, into the interior of the unit (3) and wherein the test bench (19) and/ or the equipment (20) is/ are inte grated at defined interface points (11 ) in the interior of the unit (3) and is/ are accessible via connection means (6).
2. Unit according to claim 1 , characterized in that the container (4) encloses an inner container (7).
3. Unit according to claim 1 or 2, characterized in that the unit (3) comprises at least one panel, which is double-walled and/ or which is double-walled, wherein an insulating or fire protection material is sandwiched between the two walls of the panel.
4. Unit according to one of the preceding claims, characterized in that the unit (3) comprises at least one door (8), which allows access to the interior of the unit (3).
5. Unit according to claim 4, characterized in that the door (8) comprises a fire pro tection material and/ or seals the interior of the unit (3) in a gastight manner.
6. Unit according to one of the preceding claims, characterized in that the unit (3) comprises at least one rupture disc (9) for pressure relief.
7. Unit according to one of the preceding claims, characterized in that the unit (3) comprises at least one air vent (10) for fumigation.
8. Unit according to one of the preceding claims, characterized in that the unit (3) comprises at least one hose connection (12) to lead water and / or carbon diox ide or another gas into the interior of the unit (3).
9. Unit according to one of the preceding claims, characterized in that the unit (3) comprises at least one inspection window and/ or a porthole (13).
10. Unit according to one of the preceding claims, characterized in that the unit (3) comprises means (14) to monitor electrical and thermal battery parameters.
11. Unit according to one of the preceding claims, characterized in that the unit (3) comprises a fully automatic switch-off, a fully automatic decontacting means of the entire power supply and/ or a means to create a fully automatic emergency signal, which is sent to a controller (15) and/ or to the fire brigade of a plant.
12. Unit according to one of the preceding claims, characterized in that the unit (3) comprises a means to create a fully automatic evacuation alarm.
13. Unit according to one of the preceding claims, characterized in that the unit (3) comprises means (16) to cool the interior of the unit (3) and/ or means to moni tor the unit (3) by a fire department or by the fire brigade.
14. Plant, comprising at least one unit (3) according to one of the preceding claims.
15. Plant according to claim 14, characterized in that at least one unit (3) is part of an assembly and/ or testing and/ or charging area (17) and that battery cells or battery modules (1 ) are handled by at least one industrial robot (18) and are de livered to the interior of the unit (3).
PCT/EP2019/052907 2019-02-06 2019-02-06 Unit to test and/or charge battery cells or battery modules for electrical vehicles WO2020160765A1 (en)

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WO2022150477A1 (en) * 2021-01-06 2022-07-14 Oklahoma Safety Equipment Company, Inc. Breathable overpressure assembly
KR102498967B1 (en) * 2021-11-04 2023-02-13 에프디씨 주식회사 A explosion panel assembly for a energy storage system having insulation function
KR102534686B1 (en) * 2022-03-02 2023-05-26 에프디씨 주식회사 A explosion panel assembly for a energy storage system functions of exhaust and insulation

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KR102498967B1 (en) * 2021-11-04 2023-02-13 에프디씨 주식회사 A explosion panel assembly for a energy storage system having insulation function
KR102534686B1 (en) * 2022-03-02 2023-05-26 에프디씨 주식회사 A explosion panel assembly for a energy storage system functions of exhaust and insulation

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