Dr. Ing. H.c. F. Porsche Aktiengesellschaft

Malte Jaensch

Stefan Götz

Tomas Kacetl

Jan Kacetl

Hermann Helmut Dibos

Eduard Specht

Daniel Simon

Christian Korte

Patrick Leidig

Stefan Goetz

Tim Schmidt

David Kuhn

Dirk Lappe

Axel Weyland

A method for producing a mechanical and thermal system for a modular battery. The system has a module, which involves a module housing of the module being connected, on a thermally conductive module side, to a cooling apparatus. The module includes an energy storage unit and a power electronics unit, arranged on a circuit board, which are thermally isolated from each other by a first and a second thermally conductive element, which dissipates heat to the module side thermally connected to the cooling apparatus, and are integrated in the module housing, by virtue of the energy storage unit being connected to the first thermally conductive element, which contacts the module side connected to the cooling apparatus, and by virtue of the circuit board and the energy storage unit having the second thermally conductive element arranged between them, which second thermally conductive element contacts the module side connected to the cooling apparatus.

Mechanical and thermal system for a modular battery with power electronics components

A method for state-of-charge monitoring of an AC battery, in which the battery includes a central controller having a scheduler, measuring sensors and at least two battery modules. The at least two battery modules each have at least one energy storage element and at least two power semiconductor switches, which connect the respective battery module in series or in parallel or in bypass with another battery module. The battery is controlled by the central controller, and a respective switching state of the at least two battery modules is preset by the scheduler. The state-of-charge monitoring is implemented by a control program within the scheduler. During operation of the battery, a state of each individual energy storage element is monitored by virtue of a respective current flow at a respective energy storage element being determined using continued evaluation of measured values of preset battery parameters which are detected by measuring sensors.

Method and system for state-of-charge monitoring of an AC battery

A method for AC-charging an intelligent battery pack, which is connected to a charging column and has at least two battery modules, which each comprise at least one energy storage element and at least two power semiconductor switches, which interconnect the respective battery module in series or in parallel with another battery module. The battery pack is connected for charging with alternating current provided by the charging column by a charging circuit, which includes a filter and a rectifier. According to the method, a state of each individual energy storage element is monitored. In accordance with a continued evaluation of the states of the respective energy storage elements, a terminal voltage of the battery pack is adjusted by way of dynamic actuation of the power semiconductor switches to a voltage provided by the rectifier.

AC charging of an intelligent battery

A method for switching control of a multi-level converter. The multi-level converter has a plurality of modules. A total switching state is formed from respective module switching states of the plurality of modules by the switching control. A current state of charge of all energy stores of the multi-level converter is provided continuously to the switching control. The switching control is divided into an offline part and an online part, wherein, in the offline part, a plurality of offline switching tables is calculated by way of optimizers in a continuous sequence and, for calculation of a respective offline switching table of the plurality of offline switching tables, a respective cost function is minimized according to at least one predefined offline optimization criterion for evaluating the total switching state. In the online part, an online switching table is selected from the plurality of offline switching tables in a continuous sequence.

Method and system for preselecting switching states for a multi-level converter

A method for configuring a battery for operation of at least two N-phase electric machines, in which a battery includes a plurality of energy modules, and the energy modules each have at least one energy cell and at least two power switches. A respective N-phase electric machine is assigned a respective group of the plurality of energy modules, and the assignment is carried out in accordance with an estimation of a respective energy consumption of the respective N-phase electric machines on the basis of a respective load of the respective N-phase electric machines which load is to be assumed.

Configuration of a battery of a vehicle having a plurality of drive units

An energy store () has at least three energy storage sections (u, v, w) and at least two switching elements. Each energy storage sections (u, v, w) has multiple energy storage modules and each energy storage module has at least one energy storage element that receives and stores energy from an energy source (). The energy store () is connected to a first coil () so that a voltage induced in the first coil () is used to charge the energy storage elements. The energy store () is matched to properties of the voltage provided by the first coil () by switching the switching elements. As a result, the energy storage modules of an energy storage section (u, v, w) are connected in parallel and/or in series with one another and/or at least one energy storage module of at least one energy storage section (u, v, w) is bypassed.

Method and apparatus for charging an energy store

A method for DC-charging an intelligent battery pack, which is connected to a charging column and has at least two battery modules. Each battery module includes at least two power semiconductor switches and at least one energy storage element. The battery pack is connected for charging by way of a connection circuit. A state of each individual energy storage element is monitored, wherein, in accordance with a continued evaluation of the states of the respective energy storage elements, a respective series and/or parallel interconnection of the respective battery modules among one another within the battery pack is configured dynamically by way of actuation of the power semiconductor switches.

DC charging of an intelligent battery

Method for providing cooling of a power electronics system which is integrated in a battery module, in which method the battery module has a battery housing, containing a large number of energy storage units and the power electronics system which is integrated adjacent thereto and includes a printed circuit board which is populated with power semiconductor switches, and a thermally conductive element which creates thermal contact between the respective energy storage units and the power electronics system. Cooling of the power electronics system is achieved by the thermally conductive element which renders possible transfer of thermal energy from the power electronics system to the energy storage units. At least one side of the battery housing is coupled to a cooling system. A surface area of the thermally conductive element is connected to a respective energy storage unit and is contacted by way of a respective curved portion.

Cooling for battery-integrated power electronics system

A vehicle having an energy storage element including a drive inverter and a charging unit. The energy storage element further includes a first control apparatus, modules, an interconnection apparatus, and two first poles, the drive inverter is connected to said two first poles. Each modules of said modules has an energy storage unit. The interconnection apparatus has connections between the modules and first switches provided on the connections in order to allow different interconnections of the modules and different voltages at the first poles based on a state at the first switches. Different interconnections of the modules allow at least two interconnections from the group of interconnections. The first control apparatus is configured to actuate the interconnection apparatus based on a voltage setpoint value in order to influence the different voltages at the two first poles based on the voltage setpoint value.

Vehicle having an energy storage element

An energy storage element for providing a voltage has a first control apparatus and modules, which modules each have an energy storage unit, a connection unit and a module control apparatus. The connection units are connected between two associated modules and have first switches and which connection units are designed to enable, on the basis of the state of the first switches, at least two connections from the group of connections including parallel connection of two modules, serial connection of two modules, bridging of at least one of the two modules which first control apparatus and which module control apparatus are together designed to make it possible to change the control of the associated connection unit during use of the energy storage element in order to reconfigure the energy storage element. The first control apparatus is designed to control the module control apparatuses.

Energy storage element

A method for improving the modulation index using an intelligent battery pack, in which method a battery pack includes a plurality of freely interconnectable energy modules. An energy module has at least one energy cell and at least two switches, and in which method series or parallel interconnection of a respective energy module with at least one adjacent energy module of the battery pack is implemented by a controller. A terminal voltage of the battery pack, which terminal voltage results from the respective interconnection, is adjusted in accordance with a respectively prespecified load demand on at least one N-phase electrical machine. The terminal voltage is connected as an input voltage to at least one multi-stage inverter, and an N-phase alternating current for supplying a respective N-phase electrical machine is formed by the at least one multi-stage inverter on the basis of a level of the input voltage.

Modulation index improvement by intelligent battery

A battery module for a traction battery having a housing, battery cells arranged inside the housing, a power electronics circuit board which is adjacent to the battery cells, a support face, facing away from the power electronics circuit board, for a cooling plate of the traction battery, and a heat-conducting element which bears over a surface on the power electronics circuit board and runs between the battery cells in the direction of or along the support face. Also described is a corresponding method for manufacturing a battery module, a corresponding traction battery and a corresponding electric car.

Battery module for a traction battery

The invention relates to a bar winding arrangement of a stator or a rotor of an electric machine, including a number of bar segments, which are housed in a plurality of slots of the stator or the rotor and are electrically connected to one another in such a way that they form a continuous winding of the stator or the rotor, wherein each of the slots is divided by the bar segments into a first group of bar segments and at least one second group of bar segments, wherein the bar segments of the first group have a smaller cross section than the bar segments of the second group, wherein the bar segments of the first group are electrically connected in series and the bar segments of the second group are electrically connected in series and in parallel with the bar segments of the first group and wherein the bar segments of the first group are arranged closer to a slot opening in the radial direction than the bar segments of the second group.

Bar winding arrangement of a stator or a rotor of an electric machine

A rotating electrical machine includes a rotor iron, a stator iron and conductor bars. An air gap separates the rotor iron from the stator iron. The stator iron has a slot and the conductor bars run in the slot. The conductor bars have a first profile in a first segment, the conductor bars have a second profile in a second segment and the first profile differs from the second profile. Also described is a method which is adapted for producing an electrical machine.

Rotating electrical machine and specially adapted method for producing said rotating electrical machine

A method for producing a conductor segment includes: passing a copper bar in a predetermined direction of movement through a rotating first work roll and a second work roll rotating in the opposite direction to the first work roll; rotating a first backup roll in the opposite direction to the first work roll to brace the first work roll against the copper bar with an adjustable first force directed perpendicularly to the direction of movement; rotating at least one second backup roll in the opposite direction to the second work roll to brace the second work roll against the copper bar with an adjustable second force directed counter to the first force; and adjusting the first and second forces such that the work rolls give the conductor bar a thickness that varies along its length. Also described is a corresponding device and a corresponding method for producing an electric machine.

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Bietigheim-Bissingen, Germany

Malte Jaensch