Conformal integration method and system for battery system state monitoring curved surface sensing array

Abstract

The invention belongs to the technical field of multifunctional battery system monitoring, and discloses a battery system state monitoring curved surface sensing array conformal integration method and a battery system state monitoring curved surface sensing array conformal integration system. A polyimide substrate is prepared on the surface of a battery system by using a plasma surface texturing treatment process, a sensing array is integrated on the curved surface of the battery system, and parameters of the multifunctional battery system are monitored; parameter data are transmitted to a data acquisition module, and the data acquisition module takes a microcontroller and a high-speed analog-to-digital converter as a core to realize high-precision and high-speed digital conversion of sensing data; advanced processing, analysis and visualization are carried out on the converted data, and real-time monitoring, historical data playback and complex data analysis of the data are achieved; the method and the system adapt to surface curvatures of different battery systems, realize comprehensive monitoring of the multifunctional battery system, are not limited by the shape of the battery system, and have high integration level and stability.

Description

Technical Field

[0001] The present invention relates to the technical field of multi-functional battery system monitoring, and particularly relates to a conformal integration method and system for a battery system state monitoring curved surface sensing array. Background Art

[0002] Against the backdrop of the increasingly severe global energy crisis, improving energy use efficiency and promoting renewable energy have become particularly crucial. As an innovative approach to energy conversion and storage, multi-functional battery system technology has attracted much attention because it can synchronously process multiple energy forms. However, the complexity, diversity, and high integration characteristics of such systems in design and operation pose more stringent requirements for monitoring and control technologies. Especially in the monitoring of curved surface battery system entities, the conformal fitting ability of the monitoring system has become the core element to ensure monitoring effectiveness and system stability.

[0003] The monitoring of multi-functional battery systems mainly relies on implantable sensors, such as fiber Bragg grating sensors. The specific problems faced by existing implantable sensors in curved surface monitoring include: (1) In multi-signal measurement, complex decoupling algorithms are required, which increases the difficulty and complexity of data processing; (2) The sensors have insufficient stability in complex environments and are easily damaged, especially under dynamic working conditions; (3) The size and rigidity of the sensors limit their conformal fitting ability with the curved surface battery system and may damage the energy structure; (4) The integration level is insufficient, making it difficult to synchronously measure multiple physical quantities, which limits the performance of the monitoring system; (5) The spatial resolution is insufficient, restricting the ability of distributed measurement and affecting the comprehensiveness and detail of monitoring; (6) In large-area monitoring, it is difficult to find a balance between monitoring effect and engineering cost, especially in curved surface monitoring, and this challenge is even more obvious.

[0004] Embedded micro-sensors provide an alternative. They usually have higher measurement accuracy and stability and can detect more types of physical parameters. However, these sensors are limited by their size in practical applications and are difficult to conformally fit with the curved surface battery system, and may damage the internal energy structure during the implantation process. Metal thin film temperature sensors prepared by CMOS technology, although showing the potential for conformal fitting with multi-functional battery systems, the current research limitations have led to the fact that these sensors have not yet been able to achieve integrated monitoring of multi-physical field parameters, and there are deficiencies in spatial resolution and the diversity of monitoring locations.

[0005] To overcome the above challenges, a conformal integration method for a battery system state monitoring curved surface sensing array needs to be developed to be able to adapt to the complex curved surfaces of multi-functional battery systems and achieve real-time and accurate monitoring of multi-physical field parameters.

[0006] However, the design of such a sensing array must take into account the geometric characteristics of the curved surface to ensure that the sensors can closely adhere to and adapt to any curvature changes of the energy surface. Traditional three-dimensional integrated circuits (3D-MIDs) and 3D printing technologies do not have the ability to fabricate circuits on curved surfaces. Electroplating and electroless plating methods not only have low production efficiency and are prone to defects such as holes when preparing thick conductive layers, but also are accompanied by environmental pollution problems. Although traditional screen printing methods are convenient for fabricating conductive circuits, they have poor process adaptability when printing complex curved surface conformal circuits, and the rigid screen frame may interfere with the structure of the substrate, restricting the size of the circuit pattern. Although the transfer printing method can form the entire circuit in one step, its accuracy is affected by the template, and the overall size of the printable circuit is limited. Finally, in terms of functional integration, precisely integrating functional materials into structural materials in traditional processes usually requires complex assembly and connection to achieve specific functional designs. These limitations indicate that traditional circuit manufacturing technologies have obvious deficiencies in curved surface manufacturing, and there is an urgent need to develop new technologies to overcome these challenges in order to achieve more efficient, environmentally friendly, and precise curved surface circuit manufacturing, which is of great significance for improving the performance and reliability of electronic devices.

[0007] In recent years, the breakthrough of flexible electronics technology, especially the development of advanced curved surface integrated preparation technologies such as COMS, MEMS, electrohydrodynamic jet printing, and transfer printing, has provided new possibilities for the preparation of highly integrated, miniaturized, and flexible multifunctional sensors. It not only promotes the development of the curved surface conformal multi-physical field sensing array itself, but also provides new ideas and tools for the design and implementation of the hardware acquisition system, making the multi-physical field curved surface conformal attachment monitoring of the multifunctional battery system more feasible and efficient. Summary of the Invention

[0008] In view of the above defects or improvement requirements of the prior art, the present invention provides a method and system for conformal integration of a curved surface sensing array for monitoring the state of a battery system, aiming to adapt to the complex curved surface of the multifunctional battery system and achieve real-time and accurate monitoring of multi-physical field parameters.

[0009] To achieve the above object, according to one aspect of the present invention, there is provided a method for conformal integration of a curved surface sensing array for monitoring the state of a battery system, including the following steps:

[0010] S1: According to the specific size and monitoring requirements of the battery system, determine the type and quantity of the sensing array, prepare a polyimide substrate on the surface of the battery system by using a plasma surface texturing process, and integrate the sensing array onto the curved surface of the battery system to monitor the parameters of the multifunctional battery system;

[0011] S2: Transmit the parameter data obtained in step S1 to the data acquisition module. The data acquisition module takes a microcontroller and a high-speed analog-to-digital converter as the core, and through structural design, adapts and integrates a flexible sensing array onto the surface of the battery system to achieve high-precision and high-speed digital conversion of sensing data.

[0012] S3: Perform advanced processing, analysis, and visualization on the converted data in step S2 to achieve real-time monitoring of data, playback of historical data, complex data analysis, as well as an intuitive graphical user interface for remote monitoring and diagnosis.

[0013] Preferably, the sensing array includes a temperature sensor, a strain sensor, and an acceleration sensor to monitor the temperature, strain, and acceleration parameters of the battery system.

[0014] Preferably, the plasma surface texturing process in step S1 includes the following steps:

[0015] S11: Point cloud scanning: Obtain the surface point cloud information of the battery system through point cloud scanning.

[0016] S12: Surface reconstruction: Reconstruct the surface in 3D modeling software according to the surface information scanned in step S11.

[0017] S13: Mask design: In the 3D model, design the flexible substrate range for the area where the sensing array is to be prepared on the surface constructed in step S12 according to requirements.

[0018] S14: Mask attachment: Prepare a mask on a thermal release tape using laser cutting technology, and attach the mask to the surface of the curved surface battery system obtained in step S13 to cover the parts where the curved surface sensing array does not need to be prepared.

[0019] S15: Curved surface substrate preparation: Spray polyimide solution on the areas of the surface of the curved surface battery system obtained in step S14 that are not covered by the mask using electrospray technology. After a uniform thickness of polyimide substrate is prepared on the entire target area of the curved surface sensing array, perform thermal infrared sintering to cure the polyimide substrate.

[0020] S16: Path planning for printing the curved surface sensing array: Project the curved surface sensing array obtained in step S15 onto the surface of the battery system in 3D modeling software, and perform path planning according to the line width and walking characteristics of the printing.

[0021] S17: Plasma surface texturing: Treat the surface of the curved surface substrate obtained in step S16 through plasma surface treatment to regulate the surface microstructure and chemical composition, reshape the material surface, and improve the interfacial bonding strength between the device and the substrate, thereby enhancing the stability and service life of the sensing array.

[0022] S18: Preparation of the curved surface sensing array: Conductive paste is sprayed on the surface of the curved substrate that has been treated with plasma in step S17 by means of electrohydrodynamic jet printing. The printing line width and its consistency are adjusted by controlling the printing process parameters, and the integrated preparation of the conductive circuit of the sensing array is achieved following the printing path. Finally, thermal infrared sintering is carried out to cure the sensing array.

[0023] S19: The curved surface sensing array obtained in step S18 is connected to an external measurement circuit through a lead electrode group to complete the integration of the entire monitoring system.

[0024] Preferably, step S2 specifically includes the following steps:

[0025] S21: Communicate through the sensing array and the high-speed analog-to-digital converter in step S1 to transmit the parameter data obtained by the sensing array to the high-speed analog-to-digital converter. Better resolution is obtained through the chip gain adjustment of the high-speed analog-to-digital converter to achieve precise acquisition and conversion of the sensing signal, and temperature field and strain nephogram display are carried out to realize data visualization.

[0026] S22: Transmit the data in step S21 to the microcontroller, and obtain a linear relationship through calibration curve fitting to realize the conversion between resistance and temperature, calibrate the strain sensor to realize the conversion relationship between resistance and strain, and consider temperature drift compensation to ensure the accuracy of the monitoring data.

[0027] S23: On the basis of step S22, the microcontroller is designed with multiple functions to provide adaptability and facilitate expansion and upgrade.

[0028] Preferably, the multiple-function design in step S23 includes modular design, environmental adaptability design, hardware circuit design, software design, material and structure design, and flexible structure design of the sensing array.

[0029] Modular design: Divide the hardware and software functions into independent modules, and realize collaborative work through standardized interfaces. The hardware modules include a sensor module, a data acquisition module, and a communication module, which can be flexibly increased, decreased, and upgraded according to the monitoring requirements. The software modules include sensor drivers, data processing and analysis, and user interfaces, which support user-defined algorithms and function expansion to improve the maintainability and adaptability of the system.

[0030] Environmental adaptability design: Solve the power supply problem through jumpers to improve the flexibility of the system and meet the requirements of different application scenarios. Ensure the stable operation of the system in harsh environments through environmental adaptability. At the same time, extend the service life through a low-power power management strategy, support multiple power inputs, and use components with a wide temperature range to cope with extreme conditions.

[0031] Hardware circuit design: The hardware circuit adopts filtering, shielding, and isolation technologies to reduce electromagnetic interference. Meanwhile, the communication protocol is optimized to ensure the reliability of data transmission.

[0032] Software design: At the software level, a temperature compensation algorithm is adopted to correct sensor data in real time to ensure the accuracy of monitoring results.

[0033] Material and structure design: Polyimide flexible polymer material is used as the substrate to ensure that the sensor array can closely fit the curved surface of the battery system. Meanwhile, highly conductive materials are used as conductive lines to ensure the stability of signal transmission.

[0034] Flexible structure design of the sensing array: It can adapt to complex curved surface deformation. Meanwhile, through multi-layer lead electrodes and compact integrated packaging, stable connection and miniaturization are achieved, improving the portability and installability of the system.

[0035] Preferably, step S3 specifically includes the following steps:

[0036] S31: Design a multifunctional battery system status detection interface using software platforms such as Labview or Matlab. The system interface supports real-time monitoring of data, playback of historical data, and complex data analysis.

[0037] S32: According to the user-defined data processing method, automatically calibrate the resistance, temperature, and strain of the converted data in step S2 to achieve advanced data processing, analysis, and visualization.

[0038] S33: The system in step 31 is designed with an intuitive graphical user interface and integrated with a wireless communication module. The data processed, analyzed, and visualized in step S2 is displayed graphically or remotely transmitted and network-connected through the wireless communication module to facilitate remote monitoring and diagnosis.

[0039] Preferably, the data processing method in step 32 includes the following steps:

[0040] S321: Preprocess the converted data obtained in step S2, including signal calibration, noise filtering, and data synchronization, to ensure the accuracy and consistency of the data.

[0041] S322: Extract the characteristics of physical quantities such as temperature, strain, and acceleration from the data preprocessed in step S321 to obtain change rates, extreme values, and spectral characteristics to capture key information.

[0042] S323: Conduct multi-physical quantity correlation analysis and data fusion algorithm integration on the characteristics obtained in step S322 to integrate different sensor data and improve data reliability.

[0043] S324: The data integrated through step S323 is further subjected to anomaly detection and diagnosis using threshold judgment, pattern recognition, and fault diagnosis models to quickly identify and locate potential faults.

[0044] S324: The data obtained from the anomaly detection and diagnosis in step S323 is visualized in real time through a graphical user interface, and a historical analysis report containing statistical information, anomaly events, and diagnosis results is generated to provide comprehensive support for the health management and performance optimization of the battery system.

[0045] Preferably, the following steps are further included:

[0046] S4: By real-time monitoring the status of the multifunctional battery system, anomalies are automatically detected and the recovery process is triggered to improve the reliability and stability of the system; in cooperation with the low-power module, through energy-saving modes and power management strategies, the service life of the system is extended, energy consumption is reduced, and the requirements for long-term operation are met.

[0047] To achieve the above object, according to another aspect of the present invention, a conformal integrated system for a battery system state monitoring curved surface sensing array adopts the above-mentioned method for conformal integration of a battery system state monitoring curved surface sensing array, and includes a sensing module, a data acquisition module, and a data processing and user interface system.

[0048] The sensing module uses electrohydrodynamic jet printing, electrospraying, and plasma surface texturing to prepare a polyimide substrate on the surface of the multifunctional battery system, and directly integrates the sensor onto the curved surface of the battery system to improve the interfacial bonding strength between the sensor circuit and the curved surface substrate of the battery system, and monitors the temperature, strain, and acceleration parameters of the multifunctional battery system through the sensor.

[0049] The data acquisition module adapts the input and output interfaces of the flexible sensor through structural design to achieve high-precision and high-speed digital conversion of sensor data.

[0050] The data processing and user interface system automatically calibrates the resistance with temperature and strain, realizes advanced processing, analysis, and visualization of data; through interface design, it realizes real-time monitoring of data, playback of historical data, and complex data analysis, as well as an intuitive graphical user interface and wireless communication, supporting remote data transmission and network connection, and facilitating remote monitoring and diagnosis.

[0051] Preferably, the sensing module includes several groups of sensing units, and each sensing unit includes, but is not limited to, a temperature sensor, a strain sensor, and an acceleration sensor to achieve precise monitoring of the temperature, strain, and vibration of the battery system.

[0052] The data acquisition module includes a microcontroller and a high-speed analog-to-digital converter, which is responsible for coordinating the acquisition and preprocessing of sensor data and realizing high-precision and high-speed digital conversion of sensor analog signals.

[0053] Preferably, it further includes a fault detection and system self-recovery mechanism, and a low-power module; the fault detection and system self-recovery mechanism automatically detects abnormalities and triggers the recovery process by real-time monitoring the state of the multi-functional battery system, improving the reliability and stability of the system.

[0054] The low-power module extends the service life of the system, reduces energy consumption, and meets the requirements of long-term operation through energy-saving modes and power management strategies.

[0055] Generally speaking, compared with the prior art, the above technical solution conceived by the present invention has the following beneficial effects:

[0056] Based on flexible electronic curved surface manufacturing technology and an efficient hardware acquisition system, the present invention provides a monitoring solution with high spatial resolution and high integration, which is particularly suitable for the monitoring of curved surface battery systems. The curved surface conformal multi-physical field sensing array can achieve comprehensive monitoring without being limited by the shape of the battery system. The electrohydrodynamic inkjet printing process and the plasma surface texturing process ensure the feasibility and cost-effectiveness of large-area monitoring, providing strong technical support for the health management and performance optimization of multi-functional battery systems. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] Figure 1 It is a framework design diagram of a preferred example of the present invention.

[0058] Figure 2 It is a signal acquisition and display working principle diagram of a preferred example of the present invention.

[0059] Figure 3 It is a preparation and integration process flow diagram of a preferred example of the present invention.

[0060] Wherein: 1. Lead-in and lead-out electrode group; 2. Single sensing unit; 3. Temperature sensor; 4. Horizontal strain sensor; 5. Vertical strain sensor; 6. Flexible substrate. DETAILED DESCRIPTION OF THE INVENTION

[0061] In order to enable those skilled in the art to better understand the solution of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present application.

[0062] It should be noted that the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product / device that includes a series of steps or units need not be limited to those steps or units that are clearly excluded, but may include other steps or units that are not clearly listed or are inherent to these processes, methods, systems, products or devices.

[0063] It should be noted that, without conflict, the embodiments in this application and the features in the embodiments may be combined with each other. The following will detail this application with reference to the accompanying drawings and in conjunction with the embodiments.

[0064] This embodiment discloses a conformal integration method for a battery system state monitoring curved surface sensing array, including the following steps:

[0065] S1: According to the specific dimensions and monitoring requirements of the battery system, determine the type and quantity of the sensing array, use the plasma surface texturing process to prepare a polyimide substrate on the surface of the battery system, and integrate the sensing array onto the curved surface of the battery system to monitor the parameters of the multifunctional battery system;

[0066] S2: Transmit the parameter data obtained in step S1 to the data acquisition module. The data acquisition module takes a microcontroller and a high-speed analog-to-digital converter as the core, and through structural design, adapts to the flexible sensing array integrated on the curved surface of the battery system to achieve high-precision and high-speed digital conversion of the sensing data;

[0067] S3: Perform advanced processing, analysis and visualization on the data converted in step S2 to achieve real-time monitoring of the data, playback of historical data and complex data analysis, as well as an intuitive graphical user interface and remote monitoring and diagnosis.

[0068] S4: By real-time monitoring the state of the multifunctional battery system, automatically detect anomalies and trigger recovery processes to improve the reliability and stability of the system; cooperate with the low-power module, through energy-saving modes and power management strategies, extend the service life of the system, reduce energy consumption, and meet the requirements of long-term operation.

[0069] The plasma surface texturing process in step S1 includes the following steps:

[0070] S11 Point cloud scanning: Obtain the point cloud information of the battery system surface through point cloud scanning;

[0071] S12 Surface reconstruction: Reconstruct the surface in 3D modeling software according to the surface information scanned in step S11;

[0072] S13 Mask design: In the 3D model, design the flexible substrate range for the area where the sensing array is to be prepared on the surface constructed in step S12 as required;

[0073] S14 Mask Attachment: A mask is prepared on the thermal release tape using laser cutting technology, and the mask is attached to the surface of the curved battery system obtained in step S13 to cover the parts where the curved sensing array does not need to be prepared;

[0074] S15 Curved Substrate Preparation: The polyimide solution is sprayed on the areas of the surface of the curved battery system obtained in step S14 that are not covered by the mask using electrospray technology. After a polyimide substrate with a uniform thickness is prepared on the entire target area of the curved sensing array, thermal infrared sintering is performed to cure the polyimide substrate;

[0075] S16 Printing Path Planning for the Curved Sensing Array: In the 3D modeling software, the curved sensing array obtained in step S15 is projected onto the surface of the battery system, and the path is planned according to the printed line width and the trend characteristics;

[0076] S17 Plasma Surface Texturing Treatment: The surface of the curved substrate obtained in step S16 is treated by plasma surface treatment to regulate the surface microstructure and chemical composition, reshape the material surface, and improve the interfacial bonding strength between the device and the substrate, thereby improving the stability and service life of the sensing array;

[0077] S18: Preparation of the Curved Sensing Array: The conductive paste is sprayed on the surface of the curved substrate treated by plasma in step S17 using electrohydrodynamic jet printing technology. By controlling the printing process parameters, the printed line width and its consistency are adjusted, and the integrated preparation of the conductive lines of the sensing array is achieved following the printing path. Finally, thermal infrared sintering is performed to cure the sensing array;

[0078] S19: The curved sensing array obtained in step S18 is connected to the external measurement circuit through the lead electrode group to complete the integration of the entire monitoring system.

[0079] The sensing array includes a temperature sensor (such as PT1000), a strain sensor, and an acceleration sensor (such as MPU6050) to realize the monitoring of the temperature, strain, and vibration of the battery system.

[0080] The sensor array of the present invention is directly prepared on the curved energy substrate by electrohydrodynamic jet printing technology, which allows the sensor array to maintain close contact with the battery substrate under different curvature conditions; to adapt to complex curved surfaces, the layout of the sensor units is optimized according to the curvature of the curved surface to achieve the best monitoring effect; each sensing unit integrates a strain sensor and a temperature sensor, and is connected to the external measurement circuit through a carefully designed lead electrode to ensure the stability of data transmission.

[0081] Step S2 specifically includes the following steps:

[0082] S21: Communicate with the sensing array and the high-speed analog-to-digital converter in step S1 to transmit the parameter data acquired by the sensing array to the high-speed analog-to-digital converter. Obtain better resolution through the chip gain adjustment of the high-speed analog-to-digital converter, achieve precise acquisition and conversion of the sensing signal, and perform temperature field and strain contour map display to realize data visualization;

[0083] S22: Transmit the data in step S21 to the microcontroller, and obtain a linear relationship through calibration curve fitting to realize the conversion between resistance and temperature, calibrate the strain sensor to realize the conversion relationship between resistance and strain, and consider temperature drift compensation to ensure the accuracy of the monitoring data;

[0084] S23: On the basis of step S22, the microcontroller performs a multi-functional design to provide adaptability and facilitate expansion and upgrade.

[0085] The multi-functional design in step S23 includes modular design, environmental adaptability design, hardware circuit design, software design, material and structure design, and flexible structure design of the sensing array;

[0086] Modular design is convenient for expansion and upgrade; divide the hardware and software functions into independent modules, and achieve collaborative work through standardized interfaces. The hardware modules include sensor modules (temperature sensor, strain sensor, and acceleration sensor), data acquisition modules (analog-to-digital converter, microcontroller), and communication modules (wireless communication and / or wired communication), which can be flexibly increased, decreased, and upgraded according to monitoring requirements; the software modules include sensor drivers, data processing and analysis, and user interfaces, supporting user-defined algorithms and function expansion to improve the maintainability and adaptability of the system;

[0087] Environmental adaptability design solves the power supply problem through jumpers, improves the flexibility of the system, adapts to the needs of different application scenarios, and ensures the stable operation of the system in harsh environments through environmental adaptability; at the same time, extend the service life through a low-power power management strategy, support multiple power inputs, and use components with a wide temperature range to cope with extreme conditions;

[0088] Hardware circuit design: The hardware circuit uses filtering, shielding, and isolation technologies to reduce electromagnetic interference, and at the same time optimize the communication protocol to ensure the reliability of data transmission;

[0089] Software design: At the software level, use a temperature compensation algorithm to correct the sensor data in real time to ensure the accuracy of the monitoring results;

[0090] Material and structure design: Use polyimide flexible polymer material as the substrate to ensure that the sensor array can be closely attached to the curved surface of the battery system. At the same time, use highly conductive materials as conductive lines to ensure the stability of signal transmission;

[0091] The flexible structure design of the sensing array adapts to complex surface deformations. At the same time, through multi-layer lead electrodes and compact integrated packaging, stable connection and miniaturization are achieved, improving the portability and installability of the system.

[0092] Step S3 specifically includes the following steps:

[0093] S31: Design a multifunctional battery system status detection interface using software platforms such as Labview or Matlab. The system interface supports real-time monitoring of data, historical data playback, and complex data analysis.

[0094] S32: According to the user-defined data processing method, automatically calibrate the resistance, temperature, and strain of the converted data in step S2 to achieve advanced processing, analysis, and visualization of the data.

[0095] S33: The system designed in step 31 has an intuitive graphical user interface (GUI) and integrates a wireless communication module, such as Wi-Fi or Bluetooth. The data processed, analyzed, and visualized in step S2 is displayed graphically, or remotely transmitted and network-connected through the wireless communication module to facilitate remote monitoring and diagnosis.

[0096] The data processing method in step 32 includes the following steps:

[0097] S321: Preprocess the converted data obtained in step S2, including signal calibration, noise filtering, and data synchronization, to ensure the accuracy and consistency of the data.

[0098] S322: Extract the characteristics of physical quantities such as temperature, strain, and acceleration from the data preprocessed in step S321 to obtain change rates, extreme values, and spectral characteristics to capture key information.

[0099] S323: Conduct multi-physical quantity correlation analysis and data fusion algorithms on the characteristics obtained in step S322 to integrate different sensor data and improve data reliability.

[0100] S324: Further perform anomaly detection and diagnosis on the data integrated in step S323 through threshold judgment, pattern recognition, and fault diagnosis models to quickly identify and locate potential faults.

[0101] S324: Visualize the data of anomaly detection and diagnosis in step S323 in real time through the graphical user interface and generate a historical analysis report containing statistical information, anomaly events, and diagnosis results to provide comprehensive support for the health management and performance optimization of the battery system.

[0102] The hardware acquisition system takes the STM32F401 microcontroller as the core and is responsible for coordinating the acquisition and preprocessing of sensor data. The system is configured with a high-speed analog-to-digital converter (ADC) ADS1120 to achieve high-precision and high-speed digital conversion of the analog signals from sensors. Through the full-duplex synchronous serial bus and the integrated circuit bus, the system realizes efficient data interaction with multiple ADC devices and the MPU6050 acceleration sensor. The MPU6050 monitors the vibration (acceleration) signal through the integrated circuit bus communication protocol, while the full-duplex synchronous serial bus communication protocol is used for data transmission with the ADC devices.

[0103] The data processing system is based on the Labview / Matlab software platform, providing user-defined data processing algorithms and scripts. The system supports real-time monitoring of data, playback of historical data, and complex data analysis, and intuitively displays the monitoring results through a graphical user interface (GUI). The GUI design allows users to easily configure system parameters and monitor the device status. The system is embedded with a wireless communication module, such as Wi-Fi or Bluetooth, supporting remote data transmission and network connection to achieve remote monitoring and diagnosis. In addition, the system design includes a fault detection and system self-recovery mechanism to ensure the continuity and reliability of the monitoring process.

[0104] Meanwhile, this embodiment discloses a conformal integrated system for monitoring the state of a battery system with a curved surface sensing array, including a sensing module, a data acquisition module, and a data processing and user interface system.

[0105] The sensing module uses electrohydrodynamic jet printing, electrospraying, and plasma surface texturing to prepare a polyimide substrate on the surface of the multifunctional battery system, and directly integrates the sensors onto the curved surface of the battery system to improve the interfacial bonding strength between the sensor circuit and the curved surface substrate of the battery system. The sensors monitor the temperature, strain, and acceleration parameters of the multifunctional battery system.

[0106] The data acquisition module adapts the input and output interfaces of the flexible sensors through structural design to achieve high-precision and high-speed digital conversion of sensor data.

[0107] The data processing and user interface system automatically calibrates the resistance with temperature and strain, realizes advanced processing, analysis, and visualization of data. Through the interface design, it realizes real-time monitoring of data, playback of historical data, and complex data analysis, as well as an intuitive graphical user interface and wireless communication, supporting remote data transmission and network connection, facilitating remote monitoring and diagnosis.

[0108] It also includes a fault detection and system self-recovery mechanism, as well as a low-power module. The fault detection and system self-recovery mechanism automatically detects anomalies and triggers the recovery process by real-time monitoring the state of the multifunctional battery system, improving the reliability and stability of the system.

[0109] The low-power module extends the service life of the system, reduces energy consumption, and meets the requirements of long-term operation through an energy-saving mode and a power management strategy.

[0110] The sensing module includes several groups of sensing units, and each sensing unit includes, but is not limited to, a temperature sensor, a strain sensor, and an acceleration sensor to achieve precise monitoring of the temperature, strain, and vibration of the battery system.

[0111] The data acquisition module includes a microcontroller and a high-speed analog-to-digital converter, which are responsible for coordinating the acquisition and preprocessing of sensor data and achieving high-precision and high-speed digital conversion of the analog signals of the sensors.

[0112] This preferred embodiment mainly includes: an input-output electrode group, a single sensing unit, a temperature sensor, a strain sensor, a flexible substrate, and a hardware acquisition system. The input-output electrode group is a key part for connecting the sensing array to the external measurement circuit and is composed of a group of carefully designed electrodes to ensure the stability of the electrical connection. The single sensing unit is suitable for unilateral distributed monitoring, and each sensing unit integrates two strain sensors and one temperature sensor. The strain sensors are divided into a horizontal and a vertical direction as a group to measure the strain in two directions of the battery system. Each sensing unit has two groups of strain and temperature sensors for distributed measurement to achieve more comprehensive monitoring coverage. The temperature sensor is made of PT1000 or a highly sensitive temperature-sensitive material to real-time monitor the temperature changes at different positions of the battery system. The strain sensor is used to measure the deformation of the battery system and provide key mechanical property data.

[0113] The curved conformal multi-physical field sensing array is directly prepared on the outer surface of the battery system by a roboticized electrohydrodynamic jet printing technique. As Figure 2 shown, the sensing array is prepared by electrohydrodynamic jet printing technique.

[0114] Please refer to Figure 3 , for the analog signal acquisition part. The temperature sensor and the strain sensor convert physical quantities such as ambient temperature and strain into analog electrical signals, and these signals are then sent to the ADS1120 analog-to-digital converter (ADC). This converter has 16 channels and can convert analog signals into digital signals. The ADS1120 communicates with the STM32F401 microcontroller through a full-duplex synchronous serial bus interface. The full-duplex synchronous serial bus is a high-speed synchronous serial communication protocol suitable for short-distance communication. The STM32F401, as the main control unit, sends configuration commands to the ADS1120 through the full-duplex synchronous serial bus interface and receives the converted digital signals.

[0115] In the digital signal processing stage, the STM32F401 microcontroller processes the digital signals from the ADS1120. In addition, the system also integrates a TCA9539 I2C multiplexer to expand the full-duplex synchronous serial bus interface, allowing multiple ADS1120s to share the same integrated circuit bus, thus enabling the acquisition of more sensor signals. The TCA9539 supports communication rates of 100kHz and 400kHz and exchanges data with the STM32F401 via the integrated circuit bus. In the data transmission section, the STM32F401 sends the processed data to the host computer through the RS422 interface. RS422 is a differential signal transmission technology suitable for long-distance and high-speed data transmission. The MAX3490 acts as an RS422 / RS485 transceiver, ensuring stable communication between the STM32F401 and the host computer. At the same time, the MPU6050 sensor is connected to the STM32F401 through the full-duplex synchronous serial bus interface, providing attitude or motion state information, which is processed and transmitted together with the data from the ADS1120.

[0116] Finally, in the data display stage, the host computer uses software such as LabVIEW or Matlab to receive the data from the STM32F401. These software platforms have powerful data processing and visualization capabilities, and can further analyze the received data and display it on the user interface.

[0117] Through the above embodiments, the curved surface sensing array of the present invention provides a monitoring solution with high spatial resolution, which is particularly suitable for the monitoring requirements of curved surface battery systems. Its innovative design and preparation process provide strong technical support for the technological progress and applications in related fields.

[0118] So far, the embodiments of the present disclosure have been described in detail with reference to the accompanying drawings. It should be noted that in the accompanying drawings and the text of the specification, the implementation manners that are not depicted or described are all forms known to those of ordinary skill in the art in the technical field, and no detailed description is given.

[0119] In summary, compared with the existing multi-physical field monitoring technologies for multifunctional battery systems, the multi-physical field sensing array of the present invention exhibits higher integration, monitoring resolution, stability, and reliability in curved surface monitoring, and is particularly suitable for efficient and reliable monitoring of complex curved surface battery systems, providing strong technical support for the technological progress and applications in related fields.

[0120] The above are only the preferred embodiments of the present application and are not used to limit the present application. For those skilled in the art of this technology, various changes and modifications can be made to the present application. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present application should be included within the protection scope of the present application.

Claims

1. A conformal integration method for curved surface sensor arrays for battery system status monitoring, characterized in that: The following steps are involved: S1: Determine the type and quantity of sensor arrays according to the specific size and monitoring requirements of the battery system, prepare a polyimide substrate on the surface of the battery system using a plasma surface texturing process, and integrate the sensor array onto the curved surface of the battery system to monitor the parameters of the multifunctional battery system; S2: The parameter data acquired in step S1 is transmitted to a data acquisition module. The data acquisition module is based on a microcontroller and a high-speed analog-to-digital converter. The flexible sensor array integrated on the curved surface of the battery system is adapted to achieve high-precision and high-speed digital conversion of the sensor data through a multifunctional design; S3: Perform advanced processing, analysis and visualization of the converted data in step S2 to achieve real-time data monitoring, historical data playback and complex data analysis, as well as an intuitive graphical user interface and remote monitoring and diagnosis.

2. A method for conformal integration of curved surface sensor arrays for monitoring battery system status according to claim 1, characterized in that: The sensor array includes a temperature sensor, a strain sensor and an acceleration sensor to monitor the temperature, strain and acceleration parameters of the battery system.

3. A method for conformal integration of curved surface sensor arrays for monitoring battery system status according to claim 1, characterized in that: The plasma surface roughening process in step S1 includes the following steps: S11: Point cloud scanning: obtaining the surface point cloud information of the battery system through point cloud scanning; S12: Surface reconstruction: reconstructing the surface in a 3D modeling software according to the surface information obtained by scanning in step S11; S13: Mask design: In the three-dimensional model, the flexible substrate range is designed according to the area where the sensor array is to be prepared on the curved surface constructed in step S12; S14: Mask attachment: Prepare a mask on the thermal release tape using laser cutting technology, and attach the mask to the surface of the curved battery system obtained in step S13 to cover the part where the curved sensor array does not need to be prepared; S15: Preparation of curved substrate: using electrospray technology to spray polyimide solution on the surface of the curved battery system obtained in step S14 where the mask is not covering the surface, and after the polyimide substrate of uniform thickness is prepared on the entire curved sensor array target area, thermal infrared sintering is performed to solidify the polyimide substrate; S16: curved surface sensor array printing path planning: projecting the curved surface sensor array obtained in step S15 onto the surface of the battery system in the 3D modeling software, and performing path planning according to the line width and direction characteristics of the printing; S17: plasma surface roughening treatment: the curved substrate surface obtained in step S16 is treated by plasma surface treatment to adjust the surface microstructure and chemical composition, and to reshape the material surface to enhance the interface bonding strength between the device and the substrate, thereby improving the stability and service life of the sensor array; S18: Preparation of curved surface sensor array: using electrofluidic printing technology to spray conductive slurry on the curved surface substrate surface treated by plasma in step S17, adjusting the printing line width and its consistency by controlling the printing process parameters, and realizing the integrated preparation of the conductive circuit of the sensor array by following the printing path, and finally performing thermal infrared sintering to realize the curing of the sensor array; S19: The curved surface sensing array obtained in step S18 is connected to an external measurement circuit through a lead electrode group to complete the integration of the entire monitoring system.

4. A method for conformal integration of curved surface sensor arrays for monitoring battery system status as claimed in claim 1, characterized in that: Step S2 specifically includes the following steps: S21: communicating with the sensor array of step S1 and the high-speed analog-to-digital converter to transmit the parameter data acquired by the sensor array to the high-speed analog-to-digital converter, obtaining better resolution through chip gain adjustment of the high-speed analog-to-digital converter, realizing accurate collection and conversion of sensor signals, and displaying temperature field and strain cloud diagrams to realize data visualization; S22: The data of step S21 is transmitted to the microcontroller, and a linear relationship is obtained by calibration curve fitting to realize the conversion of resistance and temperature, the strain sensor is calibrated to realize the conversion relationship between resistance and strain, and temperature drift compensation is considered to ensure the accuracy of the monitoring data; S23: Based on step S22, the microcontroller is multifunctionally designed to provide adaptability and facilitate expansion and upgrading.

5. A method for conformal integration of curved surface sensor arrays for monitoring battery system status as claimed in claim 4, characterized in that: The multifunctional design in step S23 includes modular design, environmental adaptability design, hardware circuit design, software design, material and structure design, and sensor array flexible structure design; Modular design divides hardware and software functions into independent modules, and achieves collaborative work through standardized interfaces. Hardware modules include sensor modules, data acquisition modules, and communication modules, which can be flexibly increased, decreased, and upgraded according to monitoring needs; software modules include sensor drivers, data processing and analysis, and user interfaces, and support user-defined algorithms and function expansion to improve the maintainability and adaptability of the system; Environmental adaptability design solves power supply problems through jumpers, improves system flexibility, adapts to the needs of different application scenarios, and ensures stable operation of the system in harsh environments through environmental adaptability; at the same time, it extends the service life through low-power power management strategies, supports multiple power inputs and adopts wide temperature range components to cope with extreme conditions; Hardware circuit design: The hardware circuit adopts filtering, shielding and isolation technology to reduce electromagnetic interference, while optimizing the communication protocol to ensure the reliability of data transmission; Software design: A temperature compensation algorithm is used at the software level to correct sensor data in real time to ensure the accuracy of monitoring results; The material and structural design uses polyimide flexible polymer material as the substrate to ensure that the sensor array can fit closely with the curved surface of the battery system. At the same time, high-conductivity materials are used as conductive lines to ensure the stability of signal transmission. The flexible structure design of the sensor array can adapt to the deformation of complex curved surfaces. At the same time, through multi-layer lead electrodes and compact integrated packaging, stable connection and miniaturization are achieved, improving the portability and installability of the system.

6. A method for conformal integration of curved surface sensor arrays for monitoring battery system status as claimed in claim 1, characterized in that: Step S3 specifically includes the following steps: S31: Use Labview or Matlab software platform to design a multifunctional battery system status detection interface. The system interface supports real-time data monitoring, historical data playback and complex data analysis; S32: According to the user-defined data processing method, the resistance, temperature and strain are automatically calibrated for the converted data in step S2, so as to realize advanced processing, analysis and visualization of the data; S33: The system of step 31 is designed with an intuitive graphical user interface and an integrated wireless communication module to display the data processed, analyzed and visualized in step S2 in a graphical manner, or to perform remote data transmission and network connection through the wireless communication module, so as to facilitate remote monitoring and diagnosis.

7. A method for conformal integration of curved surface sensor arrays for monitoring battery system status as claimed in claim 1, characterized in that: The data processing method in step 32 includes the following steps: S321: preprocessing the conversion data obtained in step S2, including signal calibration, noise filtering and data synchronization, to ensure the accuracy and consistency of the data; S322: extracting the characteristics of temperature, strain and acceleration physical quantities from the data pre-processed in step S321, obtaining the change rate, extreme value and spectrum characteristics, so as to capture key information; S323: Perform multi-physical quantity correlation analysis and data fusion algorithm on the features obtained in step S322 to integrate data from different sensors to improve data reliability; S324: The data integrated in step S323 is further used to perform abnormality detection and diagnosis using threshold judgment, pattern recognition and fault diagnosis models to quickly identify and locate potential faults; S324: The data detected and diagnosed in step S323 are visualized in real time through a graphical user interface, and a historical analysis report containing statistical information, abnormal events and diagnostic results is generated to provide comprehensive support for health management and performance optimization of the battery system.

8. A method for conformal integration of curved surface sensor arrays for monitoring battery system status as claimed in claim 1, characterized in that: The following steps are also included: S4: Improve system reliability and stability by monitoring the status of the multi-function battery system in real time, automatically detecting anomalies and triggering recovery processes; In conjunction with the low-power module, energy-saving mode and power management strategy are used to extend the system's service life, reduce energy consumption, and meet the needs of long-term operation.

9. A battery system status monitoring curved surface sensor array conformal integration system, using the method described in any one of claims 1 to 8, characterized in that: Including sensor module, data acquisition module, data processing and user interface system, The sensing module uses electrofluid printing, electrospraying and plasma surface texturing to prepare a polyimide substrate on the surface of the multifunctional battery system, and directly integrates the sensor onto the curved surface of the battery system to improve the interface bonding strength between the sensor circuit and the curved surface substrate of the battery system, and monitors the temperature, strain and acceleration parameters of the multifunctional battery system through the sensor; The data acquisition module adapts to the input and output interfaces of the flexible sensor through structural design to achieve high-precision and high-speed digital conversion of sensor data; The data processing and user interface system automatically calibrates resistance, temperature and strain to achieve advanced data processing, analysis and visualization; through interface design, it realizes real-time data monitoring, historical data playback and complex data analysis, as well as intuitive graphical user interface and wireless communication, supports remote data transmission and network connection, and facilitates remote monitoring and diagnosis.

10. A method for conformal integration of curved surface sensor arrays for monitoring battery system status according to claim 9, characterized in that: The sensing module includes several groups of sensing units, each of which includes but is not limited to a temperature sensor, a strain sensor and an acceleration sensor, so as to achieve accurate monitoring of the temperature, strain and vibration of the battery system; The data acquisition module includes a microcontroller and a high-speed analog-to-digital converter, which is responsible for coordinating the acquisition and preprocessing of sensor data and realizing high-precision and high-speed digital conversion of sensor analog signals; The system also includes a fault detection and system self-recovery mechanism, and a low-power module; the fault detection and system self-recovery mechanism automatically detects abnormalities and triggers a recovery process by real-time monitoring of the multi-function battery system status, thereby improving the reliability and stability of the system; The low-power module extends the service life of the system, reduces energy consumption, and meets the needs of long-term operation through energy-saving modes and power management strategies.

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