METHOD AND DEVICE FOR TESTING THE CONNECTIONS OF BATTERIES

Abstract

For testing the connections (13) of batteries (8) that are connected in a battery module (5) to several bus bars (6, 7) that are electrically in parallel with their battery electrodes (10, 11) by a resistance measurer (16) comprising a pair of contact pins (17, 18), during a measurement a first batten′ electrode (10) is contacted by a first contact pin (17) and a point on the conductor arrangement (13, 6, 13, 10) connected to the first battery electrode (10) is contacted by the second contact pin.

Claims

1-7. (canceled)

8. A method for testing connections in a battery module containing a plurality of batteries and a bus bar for connecting battery electrodes of said plurality of batteries electrically in parallel, the method comprising: contacting a first contact pin of a resistance measurer with an electrode of one of the plurality of batteries contained within the battery module; contacting a second contact pin of the resistance measurer with a point on a conductor arrangement, wherein said conductor arrangement includes the bus bar, the electrode of another of the plurality of batteries, optionally, a connector element extending between said bus bar and the electrode contacted by the first pin, and optionally, a connector element extending between said bus bar and the electrode of another of the plurality of batteries; and measuring electrical resistance between said first contact pin and said second contact pin using the resistance measurer.

9. The method according to claim 8, wherein during the measuring the second contact pin is in contact with said electrode of another of the plurality of batteries.

10. The method according to claim 9, wherein during the measuring battery electrodes of adjacent batteries in the battery module are contacted by other contact pins of the resistance measurer.

11. The method according to claim 9, wherein during the measuring several pairs of first contact pins and second contact pins of the resistance measurer contact battery electrodes and points on conductor arrangements, respectively, of other batteries contained in the battery module at the same time.

12. The method according to claim 10, wherein during the measuring several pairs of first contact pins and second contact pins of the resistance measurer contact battery electrodes and points on conductor arrangements, respectively, of other batteries contained in the battery module at the same time.

13. A device for carrying out the method according to claim 8 on a battery module in which the plurality of batteries are arranged in a fixed grid, the device comprising a test head configured to move over the grid, said test head carrying a plurality of contact pins arranged to fit the grid.

14. A device for carrying out the method according to claim 9 on a battery module in which the plurality of batteries are arranged in a fixed grid, the device comprising a test head configured to move over the grid, said test head carrying a plurality of contact pins arranged to fit the grid.

15. A device for carrying out the method according to claim 10 on a battery module in which the plurality of batteries are arranged in a fixed grid, the device comprising a test head configured to move over the grid, said test head carrying a plurality of contact pins arranged to fit the grid.

16. A device for carrying out the method according to claim 11 on a battery module in which the plurality of batteries are arranged in a fixed grid, the device comprising a test head configured to move over the grid, said test head carrying a plurality of contact pins arranged to fit the grid.

17. A device for carrying out the method according to claim 12 on a battery module in which the plurality of batteries are arranged in a fixed grid, the device comprising a test head configured to move over the grid, said test head carrying a plurality of contact pins arranged to fit the grid.

18. The device for carrying out the method according to claim 13, wherein a safety contact pin is connected by a safety resistance measurer to a contact pin of the resistance measurer, and wherein the contact pin and the safety contact pin are configured to simultaneously contact a same contactable surface.

19. The device for carrying out the method according to claim 14, wherein a safety contact pin is connected by a safety resistance measurer to a contact pin of the resistance measurer, and wherein the contact pin and the safety contact pin are configured to simultaneously contact a same contactable surface.

20. The device for carrying out the method according to claim 15, wherein a safety contact pin is connected by a safety resistance measurer to a contact pin of the resistance measurer, and wherein the contact pin and the safety contact pin are configured to simultaneously contact a same contactable surface.

21. The device for carrying out the method according to claim 16, wherein a safety contact pin is connected by a safety resistance measurer to a contact pin of the resistance measurer, and wherein the contact pin and the safety contact pin are configured to simultaneously contact a same contactable surface.

22. The device for carrying out the method according to claim 17, wherein a safety contact pin is connected by a safety resistance measurer to a contact pin of the resistance measurer, and wherein the contact pin and the safety contact pin are configured to simultaneously contact a same contactable surface.

23. The device for carrying out the method according to claim 13, wherein the contact pins are arranged and constructed on the test head such that they are extendable through holes in at least one of the bus bars of the battery module that is in the form of a plate to contact battery electrodes in the battery module under the holes.

24. The device for carrying out the method according to claim 14, wherein the contact pins are arranged and constructed on the test head such that they are extendable through holes in at least one of the bus bars of the battery module that is in the form of a plate to contact battery electrodes in the battery module under the holes.

25. The device for carrying out the method according to claim 15, wherein the contact pins are arranged and constructed on the test head such that they are extendable through holes in at least one of the bus bars of the battery module that is in the form of a plate to contact battery electrodes in the battery module under the holes.

26. The device for carrying out the method according to claim 16, wherein the contact pins are arranged and constructed on the test head such that they are extendable through holes in at least one of the bus bars of the battery module that is in the form of a plate to contact battery electrodes in the battery module under the holes.

27. The device for carrying out the method according to claim 17, wherein the contact pins are arranged and constructed on the test head such that they are extendable through holes in at least one of the bus bars of the battery module that is in the form of a plate to contact battery electrodes in the battery module under the holes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The invention is shown by way of example and schematically in the drawings. In the drawings:

[0017] FIG. 1 shows a side view of a device for testing the connections of batteries of a battery module with two test heads,

[0018] FIG. 2 shows an enlarged section along line 2-2 in FIG. 1 showing two batteries,

[0019] FIG. 3 shows a atop view onto a battery module along line 3-3 in FIG. 1,

[0020] FIG. 4 shows a view of a test head along line 4-4 in FIG. 1,

[0021] FIG. 5 shows another test head along line 5-5 in FIG. 1,

[0022] FIG. 6 shows another test head.

DETAILED DESCRIPTION OF THE INVENTION

[0023] FIG. 1 shows a side view of a test device 1 with a frame 2 that connects a module carrier 3 to a head carrier 4 and is placed, for example, with the module carrier 3 on a table or floor that is not shown. The module carrier 3 serves to receive the battery module 5 shown in FIG. 1, which is to be subjected to a test.

[0024] FIG. 2 shows a section from the battery module 5 showing a plate-like upper bus bar 6 and a lower bus bar 7 arranged parallel to it. The bus bars 6 and 7 can be constructed to be congruent and identical. A plurality of batteries 8 is arranged between them that are held standing in parallel in a uniform grid. The carrier structure 9 can serve for holding them and secures the position of all batteries among themselves and with the bus bars 6, 7.

[0025] The two batteries 8 shown are of the same type, for example, a commercial AA format. They have a longitudinally extended, cylindrical housing on whose ends battery electrodes 10 and 11 are centrally seated.

[0026] The battery electrodes 10 and 11 can be constructed to be mechanically identical, as is also shown in FIG. 2. They have a different polarity + and − and are all electrically connected in parallel. To this end the battery electrodes 10 lying toward the upper bus bar 6 and FIG. 2 and which are, for example, the + electrodes, are connected to the upper bus bar 6 and the lower battery electrodes 11 are all connected to the lower bus bar 7. In order to simplify the drawing, in FIG. 2 the electrode connections to the bus bars are only shown for the upper bus bar 6.

[0027] The upper bus bar 6 is provided with holes at the locations where the upper battery electrodes 10 are seated. Corresponding holes 12 are also formed in the lower bus bar 7.

[0028] Electrically conductive connectors 13 formed, for example, in the shape of wires or bands, are connected by one end to an upper battery electrode 10 and by the other to the upper bus bar 6. The connectors 13 can be constructed here, for example, as a wire that is soldered at its ends to the surfaces of the battery electrode 10 or is connected by spot welding.

[0029] The connectors 13 are also to be arranged in a corresponding manner between the lower battery electrodes 11 and the lower bus bar 7. They can have a relatively small cross section since they only have to carry the current of a single battery 8. The bus bars 6 and 7 must also consist of conductive material but require a greater cross section since the current of several batteries flows through them.

[0030] FIG. 3 shows a top view onto the battery module 5, the upper bus bar 6 and the holes 12 arranged in them. The holes 12 are arranged in the exemplary embodiment shown in the regular grid shown, in which the batteries 8 and the battery electrodes also stand. Two thick conductor cables 14 and 15 connect the upper bus bar 6 and the lower bus bar 7 to a consumer, for example, a vehicle engine or to control electronics connected in front of the latter.

[0031] After the mounting of the battery module 5 it must be tested for manufacturing errors. If it is assumed that the individual batteries 8 were previously tested, then the possibility of errors in the manufacture of the battery module 5 is to be found substantially in the positioning of the connectors 13.

[0032] The connectors 13 run in an S shape between the surface of the particular battery electrode 10 and the surface of the upper bus bar 6. Electrically conductive connections must be produced at both ends, for example, by spot welding.

[0033] Breaks can occur in a connector 13 or a lacking contact on one of its ends if, for example, a soldering or welding took place in an incomplete manner.

[0034] Such errors must be checked for with a test and as rapidly as possible in the case of very many connecting connections, for example, 1,000 connectors in the case of a battery module with 500 batteries.

[0035] The good conductivity of the connections between the batteries 8 and the bus bars 6, 7 is important here. A resistance measuring is carried out in order to check them. A resistance measurer is 16 is used for this that is connected by a pair of contact pins 17, 18 to the lines shown in FIG. 2.

[0036] The resistance measurer 16 comprises a current source 19 and a current measuring device 20 in a customary construction. Given a known voltage of the current source 19, the display of the current measuring device 20 can be unambiguously re-calculated into the measured resistance value. As FIG. 2 shows, in the exemplary embodiment the resistance is measured on short connections that conduct well. The resistance measurer 16 should therefore be designed in particular especially for the low-ohmic range.

[0037] In order to determine whether a connector 13 is whole and correctly connected at both ends, measurements could be carried out, for example, between the two ends of a connector in order to check it for an interruption. Then, a contacting could be made on the connecting conductor and on the other hand on the bus bar in order to test the correct connection of the connecting conductor on the bus bar.

[0038] That would mean several measurements for a connector. In addition, there is the fact that the connecting conductor 13 is sensitive and should not be touched if possible. Therefore, the measuring is carried out in such a manner as is shown in FIG. 2, namely, between two battery electrodes of different batteries connected to the same bus bar. In the example of FIG. 2 shown, that is the upper bus bar 6.

[0039] As FIG. 2 shows, two batteries 8 are measured on which the upper battery electrodes 10 are contacted by the contact pins 17 and 18. Therefore, a current flow is generated that runs from the one battery electrode through its connector 13, then through the upper bus bar 6 and then through the other connector to the battery electrode 10 of the other battery 8. Therefore, two complete battery connections are measured in series. This cuts the number of measurements and therefore the measuring time in half and optimizes the significance of the measuring.

[0040] A poor contacting of one of the contact pins 17, 18 could result in a false measurement. In order to check the reliability of the contacting, a safety measuring is carried out. For this, a safety resistance measurer 21 is provided that can have basically the same construction as the resistance measurer 16. It is connected by the two shown conductors to the contact pin 17 on the one hand and to a safety contact pin 22 on the other hand. It can be determined with this safety arrangement if both contact pins 22 and 17 are set on the same conductive surface of the battery electrode 10 whether the contact pins 17 makes a good contact with the battery electrode 10. If the measured resistance is above a set value, then the contacting of the contact pins 17 is probably insufficient and must be checked.

[0041] A corresponding safety circuit with a safety contact pin can also be provided on the contact pin 18 in order to be able to guarantee complete contact safety.

[0042] As FIG. 2 shows, the batteries 8 are connected on the bottom to the lower bus bar 7 in an identical manner. Therefore, the tests can take place here in the same manner.

[0043] The test device 1 shown in FIG. 1 serves for the testing. It carries the battery module 5 on the module carrier 3. The head carrier 4 carries two head drives 23 and 24 that for their part each carry a test head 25, 26 and can move it in the x, y and z directions in the desired manner.

[0044] The test heads 25 and 26 have different sizes and carry a number of contact pins 17, 18. Resistance measurers are connected to the contact pins in a manner that is not shown and are able to determine the resistance between two contact pins. In another embodiment it is also possible to operate all pairs of contact pins with only one resistance measurer that is constructed so that it can be switched between the pairs for this purpose.

[0045] The test heads 25 and 26 have different sizes, as FIGS. 1, 4 and 5 show. In the exemplary embodiment the test head 25 carries eight contact pins and the test head 26 carries four contact pins.

[0046] FIG. 6 shows a test head 27 with a different pin arrangement. However, the pin arrangements of all heads 25, 26 and 27 shown obviously fit the grid arrangement of the holes 12 of the battery module 5, as is shown in FIG. 3.

[0047] FIG. 1 shows the test head 25 in raised position, that is, not contacting, and shows the test head 26 in lowered position, in which the contact pins contact battery electrodes 10 of the battery module 5.

[0048] When the top of the battery module 5 has been completely tested, the battery module can be turned around in order to now test the bottom in the same manner.

[0049] In the case of a very large battery module 5, test heads 25 with very many pins, for example, the eight pins of the test head 25 shown, can be used. Of course, even much greater test heads can be used in order to further accelerate the testing process.

[0050] A test head, for example, the test head 25, can obviously be seen on the surface of the battery module 5 successively in several adjacent positions with contacting of all its contact pins, which makes it possible to achieve a complete engagement of all holes 12. As FIG. 1 shows even test heads 25 and 26 with different sizes can be used. For example, narrow ranges can be tested with the smaller test head 26 that are too narrow for the large test head 25.

[0051] In the case that safety contact pins 22 are used, they are to be additionally provided on a test head, which can double the number of contact pins on a test head.

[0052] FIG. 2 shows the geometry of the connectors 13 that are arranged in such a manner that they pass through a hole 12 of the bus bar 6. They are sensitive to touch in this area and should not be touched by the contact pins 17, 18. The contact pins 17, 18 and optionally also 22 must therefore be positioned through the hole 12 and adjacent to the connectors 13, that is, in a very narrow area range. The position control of the head drives 23 and 24 is to be constructed in an appropriately precise manner.

LIST OF REFERENCE NUMERALS

[0053] 1 Test device 15 Conductor cable

[0054] 2 Frame 16 Resistance measurer

[0055] 3 Module carrier 17 Contact pin

[0056] 4 Head carrier 18 Contact pin

[0057] 5 Battery module 19 Current source

[0058] 6 Upper bus bar 20 Current measuring device

[0059] 7 Lower bus bar 21 Safety resistance measurer

[0060] 8 Battery 22 Safety contact pin

[0061] 9 Carrier structure 23 Head drive

[0062] 10 Battery electrode 24 Head drive

[0063] 11 Battery electrode 25 Test head

[0064] 12 Hole 26 Test head

[0065] 13 Connector 27 Test head

[0066] 14 Conductor cable