A method, system and storage medium for expanding the capacity of the plates of a fiber lead acid gel battery

Abstract

The application relates to the technical field of battery repair, and discloses a method and system for expanding the plates of a fiber lead-acid gel battery and a storage medium, the method comprising: placing the battery in a conductive liquid in a liquid storage tank body, so that the battery top cover is immersed in the liquid; during repair, a first alternating current is applied to the two plates of the battery by a high-voltage generator; the repair process comprises high-temperature and vibration processes; when the high-temperature process is performed alone, the first current is adjusted in negative correlation with the real-time temperature; when the vibration process is performed alone, the first frequency is adjusted in negative correlation with the real-time vibration value; when the two processes are performed simultaneously, the first frequency adjustment step is controlled in positive correlation with the temperature rise speed, and the first current adjustment step is controlled in negative correlation with the vibration value change speed. The method can uniformly distribute the current, avoid secondary damage to the battery, efficiently remove lead sulfate crystals and repair the structure of active substances, restore the effective reaction area of the plates, narrow the gap between the actual capacity and the nominal capacity of the battery, and improve the performance stability and service life.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of battery repair, in particular to a method and system for expanding the plates of a fiber lead-acid gel battery and a storage medium. BACKGROUND

[0002] The fiber lead-acid gel battery is an improved lead-acid battery, the electrolyte of which is in a gel state with SiO2 gel as a skeleton, and the sulfuric acid electrolyte is wrapped therein, and fiber materials such as adsorbing fiber cotton are used, so that the battery has the characteristics of no free liquid, good sealing, resistance to deep discharge and the like. The plate vulcanization of the battery refers to the phenomenon that during the charging and discharging process, crystalline lead sulfate is generated on the surface of the plate, which is difficult to dissolve, and these crystals gradually accumulate and cover the plate, hindering ion exchange, leading to capacity reduction and performance deterioration of the battery.

[0003] The existing technology aims at the plate vulcanization problem of the fiber lead-acid gel battery, including an electrolyte repair method, which adds sodium sulfate, organic acid and other additives to inhibit the crystallization of lead sulfate or promote the dissolution thereof; a negative pulse charging method, which uses negative pulse current to impact the crystals; and a physical scraping method for removing the plate crystals.

[0004] The existing technology can alleviate the plate vulcanization of the fiber lead-acid gel battery, but during the vulcanization process, the active material of the plate has already suffered irreversible structural damage, such as agglomeration of active material particles and blockage of pores, so that even if the crystalline sulfate is removed, the effective reaction area of the plate is difficult to completely recover, and the capacity is still greatly reduced after the plate vulcanization is alleviated. The actual capacity of the battery is greatly different from the nominal capacity. SUMMARY

[0005] In order to repair the plates of the fiber lead-acid gel battery and improve the capacity, the application provides a method and system for expanding the plates of a fiber lead-acid gel battery and a storage medium.

[0006] In a first aspect, the application provides a method for expanding the plates of a fiber lead-acid gel battery, which adopts the following technical solution:

[0007] A method for expanding the plates of a fiber lead-acid gel battery, comprising the following steps:

[0008] The fiber lead-acid gel battery is placed in a liquid storage tank body storing a conductive liquid, so that the conductive liquid is immersed into the top cover of the fiber lead-acid gel battery;

[0009] During the repair process of the fiber lead-acid gel battery, a high-voltage generator is used to apply a first alternating current to the two plates of the fiber lead-acid gel battery, the voltage of the first alternating current is a first voltage, the current of the first alternating current is a first current, and the frequency of the first alternating current is a first frequency;

[0010] The repair process includes a high-temperature repair process and a vibration repair process;

[0011] In the time period when the high-temperature repair process is executed alone, a real-time temperature value of the fiber lead-acid gel battery is obtained, and the first current is inversely related to the real-time temperature value, that is, the lower the real-time temperature value, the greater the first current, and the higher the real-time temperature value, the smaller the first current;

[0012] In the time period when the vibration repair process is executed alone, a real-time vibration value of the fiber lead-acid gel battery is obtained, and the first frequency is inversely related to the real-time vibration value, that is, the greater the real-time vibration value, the lower the first frequency, and the smaller the real-time vibration value, the higher the first frequency;

[0013] In the time period when the high-temperature repair process and the vibration repair process are executed simultaneously, the adjustment step of the first frequency is positively related to the temperature rise speed of the real-time temperature value, that is, the faster the temperature rise speed, the greater the adjustment step of the first frequency, and the slower the temperature rise speed, the smaller the adjustment step of the first frequency; and the adjustment step of the first current is inversely related to the change speed of the real-time vibration value, that is, the faster the change speed, the smaller the adjustment step of the first current, and the slower the change speed, the greater the adjustment step of the first current.

[0014] By adopting the above technical solution, the battery is immersed in the conductive liquid, which can not only ensure uniform distribution of the current on the surface of the plate to avoid secondary damage caused by local current concentration, but also provide a stable reaction environment for subsequent repair processes; the high-temperature and vibration repair processes are executed in stages and matched with differentiated parameter adjustment logic; in the high-temperature process, the first current is inversely related to the real-time temperature, which can utilize the current Joule heat to promote the dissolution of lead sulfate crystals, while precisely controlling the temperature to prevent the structure of the active material of the plate from being damaged by high temperature; in the vibration process, the first frequency is inversely related to the real-time vibration value, which can disperse the agglomerated active material particles on the surface of the plate with suitable vibration energy, dredge the pores, and avoid mechanical damage to the plate caused by high-frequency vibration; and when the two processes are executed simultaneously, the adjustment step of the frequency is positively related to the temperature rise speed, and the adjustment step of the current is inversely related to the change speed of the vibration value, which can realize the coordinated adaptation of temperature and vibration, efficiently remove lead sulfate crystals, and maximize the repair of irreversible structural damage to the active material and the recovery of the effective reaction area of the plate, thereby greatly reducing the difference between the actual capacity and the nominal capacity of the battery and improving the performance stability and service life of the battery; in addition, the high-voltage corona generated on the plate by the alternating working frequency high voltage discharges and carbonizes the electrolyte fiber cotton, which can convert part of the fiber cotton into activated carbon and make it part of the plate, which not only hinders future plate vulcanization aging, but also significantly expands the surface area of the plate to form an effect similar to a graphene electrode, and because the electrolyte fiber cotton usually has a volume redundancy, carbonizing only a small part of the fiber cotton close to the plate will not reduce the electrolyte storage, but can greatly increase the plate area, ultimately compensating for the capacity loss of the aging battery, and even making the battery capacity exceed the original nominal capacity by about 5%.

[0015] Optionally, the value of the first voltage is gradually increased according to a preset increasing curve in a preset starting time period;

[0016] The rated capacity and the residual capacity of the fiber lead acid gel battery are acquired, and the loss capacity is calculated according to the rated capacity and the residual capacity;

[0017] The starting time period is inversely related to the loss capacity, that is, the greater the loss capacity, the shorter the starting time period, and the smaller the loss capacity, the longer the starting time period;

[0018] If the loss capacity is less than a preset reference capacity, the curvature of the increasing curve is less than 0, otherwise, the curvature of the increasing curve is greater than 0.

[0019] By adopting the above technical solution, the first voltage is gradually increased according to the preset increasing curve in the preset starting time period, which can avoid the sudden rise of the voltage to impact the aged plate, prevent the active material from falling off and the fiber cotton from carbonization out of control, and ensure the safety in the early stage of repair. At the same time, the loss capacity is calculated according to the rated capacity and the residual capacity, and the starting time period is inversely related to the loss capacity. The heavier the damage (the greater the loss capacity), the shorter the starting time period, the faster the repair voltage is reached to improve the efficiency, and the better the state (the smaller the loss capacity), the longer the starting time period, and the active material is protected by gentle voltage rise. The curvature of the curve is adjusted according to the comparison between the loss capacity and the reference capacity. If the damage is light, a gentle curve (curvature less than 0) is used to accurately control the intensity, and if the damage is heavy, an accelerated curve (curvature > 0) is used to quickly reach the repair voltage.

[0020] Optionally, in the preset starting time period, the temperature rise speed is calculated according to the real-time temperature value;

[0021] If the loss capacity is less than a preset reference capacity, the curvature of the increasing curve is inversely related to the temperature rise speed, that is, the faster the temperature rise speed, the greater the curvature, and the slower the temperature rise speed, the smaller the curvature;

[0022] If the loss capacity is greater than a preset reference capacity, the curvature of the increasing curve is positively related to the temperature rise speed, that is, the faster the temperature rise speed, the smaller the curvature, and the slower the temperature rise speed, the greater the curvature.

[0023] By adopting the above technical solution, when the damage is light, the faster the temperature rise, the greater the curvature to gently rise the voltage to protect the plate and prevent secondary problems, and the slower the temperature rise, the smaller the curvature to protect the efficiency; when the damage is heavy, the faster the temperature rise, the smaller the curvature to gently rise the voltage to prevent damage out of control, and the slower the temperature rise, the greater the curvature to promote the voltage to reach the repair threshold to improve the efficiency.

[0024] Optionally, the high-temperature repair process includes a microwave heating process. The microwave heating process is based on a magnetron, a conical waveguide, a mica diffuser, and a microwave DC power supply. The power supply terminal of the magnetron is connected to a DC high-voltage cable and then to the high-voltage DC output terminal of the microwave DC power supply. The signal output terminal of the magnetron is connected to the conical waveguide and then to one side of the mica diffuser. The other side of the mica diffuser is in close contact with one side of the fiber lead-acid gel battery.

[0025] By adopting the above technical solution, from a hardware perspective, the magnetron is connected to a microwave DC power supply via a DC high-voltage cable to ensure continuous microwave output. A conical waveguide directionally conducts and converges the microwaves, and a mica diffuser (attached to the side of the battery) ensures uniform microwave diffusion, guaranteeing precise energy application to the plates and preventing uneven heating. From a principle perspective, the high lead content of the plates strongly absorbs microwaves and converts them into heat energy, achieving rapid directional heating with higher efficiency than traditional Joule heating. Furthermore, combined with ultrasonic oscillation, its energy assists in breaking down the sulfate crystal structure. In conjunction with microwaves, it promotes the volatilization of crystalline hydrates, accelerates the transformation of crystals into non-crystallized forms, and improves the removal speed.

[0026] Optionally, during the startup period, the magnitude of the first current is controlled according to a preset sine wave curve;

[0027] The ratio of the lost capacity to the reference capacity is the capacity ratio.

[0028] The ratio of the calculated temperature rise rate to the preset reference rate is the temperature rise ratio.

[0029] The battery attribute ratio is calculated using a ratio algorithm based on the capacity ratio and temperature rise ratio.

[0030] The frequency of the sine wave curve is adjusted according to the positive correlation between the battery attribute ratio and the frequency. The larger the battery attribute ratio, the higher the frequency, and the smaller the battery attribute ratio, the lower the frequency.

[0031] By adopting the above technical solution and using a sine wave curve to control the current, it is possible to avoid sudden rises and falls in current that could impact the aging plates, reduce the shedding of active materials, and provide a stable energy foundation for subsequent processes. By calculating the capacity ratio (quantifying the degree of aging) and the temperature rise ratio (reflecting the thermal response), combined with the obtained battery attribute ratio, the relationship between "damage degree - real-time thermal state" can be comprehensively characterized, providing a comprehensive basis for current regulation. The sine wave frequency is adjusted according to the positive correlation of the battery attribute ratio. When the ratio is large, the frequency is increased to enhance the effect and prevent overheating, while when the ratio is small, the frequency is decreased to maintain the effect and prevent loss.

[0032] Optionally, the vibration repair process includes an ultrasonic vibration process, which is based on an ultrasonic diffuser plate, an ultrasonic transducer, and a high-frequency ultrasonic power supply; one side of the ultrasonic diffuser plate is in close contact with the bottom surface of the battery, the other side of the ultrasonic diffuser plate is connected to the ultrasonic signal output terminal of the ultrasonic transducer, and the signal input terminal of the ultrasonic transducer is connected to the signal output terminal of the high-frequency ultrasonic power supply.

[0033] By adopting the above technical solution, from a hardware perspective, the ultrasonic transducer receives high-frequency ultrasonic power signals and converts them into vibrational energy. This energy is then uniformly transmitted to the electrode area via an ultrasonic diffuser plate that is closely attached to the bottom of the battery, preventing energy dispersion and ensuring that the ultrasonic waves act precisely on the sulfate crystals. From a principle perspective, the high-frequency vibration of the ultrasonic oscillation breaks the sulfate crystals into easily soluble powder. At the same time, the colloidal electrolyte forms a cavity effect under the action of ultrasound, breaking the colloidal structure and creating channels for the penetration of special electrolytes. This achieves solid-state dissolution and fusion, promoting the reaction between the electrolyte and the sulfate powder to remove sulfation products.

[0034] Optionally, vibration values ​​are acquired based on multiple vibration sensors, and real-time vibration values ​​are calculated based on the multiple vibration values;

[0035] The target vibration value of the ultrasonic vibration is obtained, and the vibration attenuation value is calculated based on the target vibration value and the real-time vibration value. The frequency of the sine wave curve is adjusted according to the inverse correlation of the vibration attenuation value. The larger the vibration attenuation value, the lower the frequency; the smaller the vibration attenuation value, the higher the frequency.

[0036] By adopting the above technical solution and using multiple vibration sensors to collect data, the vibration state of each area of ​​the battery can be captured more comprehensively and accurately, avoiding local data deviations and providing a reliable basis for adjustment; the vibration attenuation value of the target and real-time vibration values ​​can be calculated to accurately quantify vibration energy loss and clarify the gap with the repair requirements; the sine wave frequency is adjusted according to the inverse correlation of the attenuation value; when the attenuation is large, the frequency is reduced to reduce interference and stabilize the vibration output; when the attenuation is small, the frequency is increased to strengthen the drive and maintain the vibration intensity.

[0037] Optionally, during the start-up period of ultrasonic vibration, the vibration rate of change of vibration attenuation value is calculated;

[0038] The maximum amplitude of the first current is adjusted according to the inverse correlation of the vibration change rate. The greater the vibration change rate, the smaller the maximum amplitude, and vice versa.

[0039] By adopting the above technical solution, the vibration change rate of the vibration attenuation value can be calculated in real time, which can keenly capture the dynamic trend of energy loss and provide a real-time basis for current adjustment, avoiding adjustment lag; the maximum value of the first current is adjusted according to the inverse correlation of the vibration change rate; when the change rate is large, the amplitude is reduced to prevent the vibration system from being overdriven, causing damage to the electrode plate and additional heat loss, and ensuring thermal safety; when the change rate is small, the amplitude is increased to provide sufficient driving energy for the ultrasonic transducer, promote stable vibration intensity to meet the standard, and avoid affecting crystal breakage and cavity effect.

[0040] Secondly, this application provides a plate capacity expansion system for fiber lead-acid gel batteries, which adopts the following technical solution:

[0041] A plate capacity expansion system for a fiber lead-acid gel battery includes a processor that performs the steps of the plate capacity expansion method for a fiber lead-acid gel battery as described in any of the preceding claims.

[0042] Thirdly, this application provides a storage medium, which adopts the following technical solution:

[0043] A storage medium storing a program, which, when executed by a processor, implements the steps of the plate expansion method for a fiber lead-acid gel battery as described in any one of the preceding claims.

[0044] In summary, this application includes at least one of the following beneficial technical effects: Through the synergy of microwave local heating and ultrasonic oscillation, it achieves efficient external repair of battery plate sulfation, breaking through the long-standing technical bottleneck of difficult repair of gel maintenance-free batteries and significantly extending the entire lifespan of lead-acid batteries. During the repair process, the battery does not need to be disassembled or dismantled, nor does it require additional liquid addition; the sulfation crystals on the plates can be completely removed. More importantly, while repairing the sulfation problem, this technology can also expand and increase the battery capacity. It solves the pain points of traditional repair methods, such as complex operation and easy damage to the battery structure, and overcomes the limitation that "repair can only restore capacity but cannot exceed the original level," providing a more convenient and efficient solution for the efficient operation and maintenance and performance upgrade of gel maintenance-free lead-acid batteries. Attached Figure Description

[0045] Figure 1 This is a schematic diagram of the electrode expansion device for fiber lead-acid gel batteries.

[0046] Figure 2 This is a flowchart illustrating the steps of the plate expansion method for fiber lead-acid gel batteries.

[0047] Reference numerals in the attached figures: 1. Fiber-insulated lead-acid gel battery; 2. Liquid storage tank; 3. Magnetron; 4. DC high-voltage cable; 5. Conical waveguide; 6. Mica diffuser; 7. Microwave DC power supply; 8. Ultrasonic diffuser plate; 9. Ultrasonic transducer; 10. High-frequency ultrasonic power supply; 11. Power frequency high-voltage generator; 12. Conductive liquid; 13. High-resistance high-voltage cable. Detailed Implementation

[0048] The embodiments of this application are described in detail below, and examples of the embodiments are shown in the accompanying drawings.

[0049] In the description of this specification, the references to "certain embodiments," "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples" refer to specific features, structures, materials, or characteristics described in connection with the described embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0050] Reference Figure 1 A plate expansion device for fiber lead-acid gel batteries is used to repair the sulfation of the plates of fiber lead-acid gel batteries 1 and expand their capacity. Its structure includes a liquid storage component, a microwave heating component, an ultrasonic vibration component, and a high-voltage power supply component. The liquid storage component includes a square liquid storage tank 2 and a conductive liquid 12. The volume of the liquid storage tank 2 is larger than the volume of the fiber lead-acid gel battery 1 to be treated. The conductive liquid 12 is filled in the liquid storage tank 2 and submerged to the height of the top cover of the fiber lead-acid gel battery 1 to ensure uniform current distribution on the plates.

[0051] The microwave heating assembly consists of a magnetron 3, a DC high-voltage cable 4, a conical waveguide 5, a mica diffuser 6, and a microwave DC power supply 7. The magnetron 3 has an oscillation frequency of 2450MHz. Its power supply terminal is connected to the high-voltage DC output terminal of the microwave DC power supply 7 via the DC high-voltage cable 4. Its signal output terminal is connected to the conical waveguide 5 and then to one side of the mica diffuser 6. The other side of the mica diffuser 6 is in close contact with one side of the fiber lead-acid gel battery 1, which is used to emit microwaves to the electrode plate to achieve local heating.

[0052] The ultrasonic vibration assembly includes an ultrasonic diffuser plate 8, an ultrasonic transducer 9, and a high-frequency ultrasonic power supply 10. One side of the ultrasonic diffuser plate 8 is in close contact with the bottom surface of the fiber lead-acid gel battery 1, and the other side is connected to the ultrasonic signal output terminal of the ultrasonic transducer 9. The signal input terminal of the ultrasonic transducer 9 is connected to the signal output terminal of the high-frequency ultrasonic power supply 10 to provide ultrasonic oscillation energy.

[0053] The high-voltage power supply component consists of a power frequency high-voltage generator 11 and a high-resistance high-voltage cable 13. The positive and negative terminals of the fiber lead-acid gel battery 1 are connected to the high-voltage output terminal of the power frequency high-voltage generator 11 through the high-resistance high-voltage cable 13. The low-voltage output terminal of the power frequency high-voltage generator 11 is electrically connected to the conductive liquid 12 in the liquid storage tank 2 through another high-resistance high-voltage cable 13, which is used to apply alternating current to the plates and generate high-voltage corona.

[0054] Example 1: Implementation of Basic Repair and Expansion Process

[0055] Embodiment 1 of this application discloses a method for expanding the capacity of the electrode plates of a fiber lead-acid gel battery, referring to... Figure 1 and Figure 2 A plate capacity expansion device based on components including a fiber lead-acid gel battery 1, a square liquid storage tank 2, a 2450MHz magnetron 3, an ultrasonic diffuser plate 8, and a power frequency high-voltage generator 11 is developed. This device is suitable for the repair and capacity expansion of 12V / 100Ah aged fiber lead-acid gel batteries 1. The specific method includes the following steps:

[0056] The fiber lead-acid gel battery 1 is placed in the storage tank 2 containing conductive liquid 12, so that the conductive liquid 12 is submerged up to the top cover of the fiber lead-acid gel battery 1. In this embodiment, a square storage tank 2 with a volume of 50L is selected, which is larger than the volume of the 12V / 100Ah battery to ensure that the battery can be placed stably and that there is space for the conductive liquid 12 to flow. Dilute sulfuric acid conductive liquid 12 with a concentration of 1.28g / cm³ is injected into the tank. Dilute sulfuric acid conductive liquid 12 has both good conductivity and chemical stability and will not corrode the battery casing and plates. Slowly place the 12V / 100Ah fiber lead-acid gel battery 1 to be repaired into the center of the liquid storage tank 2. Adjust the battery position so that the conductive liquid 12 is completely submerged to the top cover of the battery, with the liquid level 1-2cm higher than the top cover. This submersion depth ensures that the positive and negative plates of the battery are in full contact with the conductive liquid 12, forming a uniform current path and avoiding secondary damage such as plate burns and active material shedding caused by local current concentration (such as excessively high current density at the edge of the plate) during subsequent power-on. At the same time, the conductive liquid 12 can also serve as a heat conduction medium to balance the temperature distribution in the subsequent high-temperature repair process and prevent local sudden cooling and heating of the battery.

[0057] During the repair process of the fiber lead-acid gel battery 1, a first alternating current is applied to the two plates of the fiber lead-acid gel battery 1 using a high-voltage generator. The voltage of the first alternating current is the first voltage, the current of the first alternating current is the first current, and the frequency of the first alternating current is the first frequency. The high-voltage output terminal of the power frequency high-voltage generator 11 is connected to the positive terminal (12mm in diameter) and the negative terminal of the fiber lead-acid gel battery 1 respectively through two high-resistance high-voltage cables 13 with a cross-sectional area of ​​2.5mm². The cable joints are sealed with insulating tape to prevent the conductive liquid 12 from seeping in and causing a short circuit. At the same time, the low-voltage output terminal of the power frequency high-voltage generator 11 is electrically connected to the conductive liquid 12 in the liquid storage tank 2 through another high-resistance high-voltage cable 13. A metal conductive plate is fixed to the end of the cable to increase the contact area with the liquid. Start the power frequency high voltage generator 11 and apply the first AC current to the two plates of the battery. The initial parameters are set as follows: first voltage 14V, which is 1.17 times the nominal voltage of the battery to avoid the initial voltage being too high and impacting the plates; first current 1.5A, which is 0.02C lower than the rated discharge current of the battery to reduce the load of the initial current on the aging plates; first frequency 50Hz, which is adapted to the normal output characteristics of the power frequency high voltage generator 11 to ensure current stability.

[0058] The repair process includes high-temperature repair and vibration repair procedures:

[0059] Operating Condition 1-1: High-temperature repair procedure is performed separately.

[0060] During the separate execution phase of the high-temperature repair process, the magnetron 3 assembly is activated. Magnetron 3 is connected to the microwave DC power supply 7 via a DC high-voltage cable 4. The signal is transmitted through a conical waveguide 5 to the mica diffuser 6, which is in close contact with the battery side. Microwave heating and Joule heating work together to promote the dissolution of lead sulfate crystals on the electrode plates. Temperature control is used to prevent damage to the electrode plates. A PT100 temperature sensor installed on the side wall of the storage tank 2, close to the battery electrode area, collects the real-time battery temperature value at a frequency of once every 10 seconds. The collected data is transmitted to the control system for analysis. The first current is adjusted inversely based on the real-time temperature value; that is, the lower the real-time temperature, the larger the first current; and the higher the real-time temperature, the smaller the first current.

[0061] Case 1-1-1: When the real-time temperature is 45℃, which is lower than the preset target lower limit of 50℃, it indicates that the current heat is insufficient and the lead sulfate crystals dissolve slowly. The first current is increased from 1.5A to 2.5A. After the current is increased, the Joule heat generation increases. The microwave heating and current heating work together to make the plate temperature rise at a rate of 0.8℃ / min, gradually approaching the target temperature range.

[0062] Case 1-1-2: When the real-time temperature rises to 62℃, which is higher than the preset target temperature limit of 60℃, it indicates that there is excess heat, which may cause the active material of the electrode plate, lead dioxide, to sinter. The first current is reduced from 2.5A to 0.8A. After the current is reduced, the Joule heat is reduced. With the heat dissipation effect of the conductive liquid 12, the electrode plate temperature drops at a rate of 0.5℃ / min and returns to the safe range.

[0063] Case 1-1-3: When the real-time temperature value is stable at 55℃, it is within the target range of 50-60℃. The first current of 1.8A is kept constant to ensure that the lead sulfate crystals dissolve efficiently at the appropriate temperature, while avoiding damage to the active material.

[0064] Operating Conditions 1-2: Vibration repair procedures are performed separately.

[0065] In this stage, the ultrasonic component is activated. The ultrasonic transducer 9 is powered by a high-frequency ultrasonic power supply 10. The vibration energy is transmitted to the electrode plates through the ultrasonic diffuser plate 8, which is closely attached to the bottom of the battery. The high-frequency vibration breaks up the aggregated active material on the electrode plates, and mechanical damage is avoided by adjusting the vibration intensity. Three piezoelectric vibration sensors installed on the front, side, and bottom of the battery collect vibration values ​​in each area at a frequency of 1 time / 5 seconds. The control system takes the arithmetic mean of the data from the three sensors to obtain the real-time vibration value, avoiding the bias of data from a single sensor. The first frequency is adjusted according to the inverse correlation of the real-time vibration value; that is, the larger the real-time vibration value, the lower the first frequency; the smaller the real-time vibration value, the higher the first frequency.

[0066] Case 1-2-1: When the real-time vibration value is 55μm, it is higher than the preset target vibration value upper limit of 50μm, indicating that the vibration energy is excessive and may cause the electrode plate to crack. The first frequency is reduced from 50Hz to 35Hz. After the frequency is reduced, the periodic change of the current slows down, the driving intensity of the ultrasonic transducer 9 is weakened, and the real-time vibration value decreases to 48μm at a rate of 3μm / min, avoiding mechanical damage to the electrode plate.

[0067] Case 1-2-2: When the real-time vibration value drops to 28μm, which is lower than the preset target vibration value lower limit of 30μm, it indicates that the vibration energy is insufficient and cannot effectively disperse the aggregated particles. The first frequency is increased from 35Hz to 60Hz. After the frequency is increased, the current driving effect is enhanced, and the real-time vibration value increases to 32μm at a rate of 2μm / min, reaching the effective vibration intensity.

[0068] Case 1-2-3: When the real-time vibration value is stable at 42μm, it is within the target range of 30-50μm. The first frequency of 45Hz is maintained to ensure that the vibration energy can both disperse the active material particles aggregated on the surface of the electrode, such as residual particles from lead sulfate reduction, and unclog the pores of the electrode, which is conducive to the subsequent penetration of electrolyte.

[0069] Operating conditions 1-3: High temperature and vibration repair procedures are performed simultaneously.

[0070] During the stage where the high-temperature repair process and the vibration repair process are executed simultaneously, the magnetron 3 and the ultrasonic component are activated at the same time. Through the coordinated regulation of temperature and vibration, the deep removal of lead sulfate crystals and the repair of active substances are achieved. The regulation logic is as follows: the faster the temperature rises, the larger the first frequency adjustment step size; the faster the vibration value changes, the smaller the first current adjustment step size.

[0071] Calculate the rate of temperature rise per unit time, which is the difference between two adjacent temperatures / time interval. The rate of temperature rise is positively correlated with the first frequency adjustment step size.

[0072] Case 1-3-1: When the temperature rise rate is 4℃ / min, which is 2℃ / min higher than the preset ideal rate, it indicates that the temperature rises too fast. The frequency adjustment needs to be accelerated to enhance vibration heat dissipation. The first frequency adjustment step is increased from 5Hz / time to 10Hz / time. The original frequency is 45Hz, and after one adjustment, it is directly increased to 55Hz. The vibration intensity is enhanced, and the temperature rise rate is reduced to 2.2℃ / min, returning to the ideal range.

[0073] Case 1-3-2: When the temperature rise rate is 1℃ / min, it is lower than the ideal rate, indicating that the temperature rise is slow. The frequency adjustment needs to be slowed down to maintain vibration stability. The first frequency adjustment step size is reduced from 10Hz / time to 3Hz / time. The original frequency is 55Hz, and after one adjustment, it is increased to 58Hz. The vibration intensity increases gradually, and the temperature rise rate increases to 1.8℃ / min, which is close to the ideal rate.

[0074] The rate of change of vibration value per unit time is calculated, which is the difference between two adjacent vibration values ​​divided by the time interval. The rate of change is inversely correlated with the first current adjustment step size.

[0075] Case 1-3-3: When the vibration value changes at a rate of 12 μm / min, which is 5 μm / min higher than the preset ideal rate, it indicates that the vibration fluctuation is severe. The current adjustment needs to be slowed down to avoid interference. The first current adjustment step is reduced from 0.5A / time to 0.2A / time. The original current is 1.8A, and after one adjustment, it is increased to 2.0A. The current increases slowly, and the vibration value changes at a rate of 6 μm / min, tending to stabilize.

[0076] Case 1-3-4: When the vibration value changes at a rate of 2 μm / min, which is lower than the ideal rate, it indicates that the vibration state is stable. The current adjustment can be accelerated to enhance the heat. The first current adjustment step is increased from 0.2A / time to 0.6A / time. The original current is 2.0A, and after one adjustment, it rises to 2.6A. The current increases rapidly, the synergistic effect of temperature and vibration is enhanced, and the efficiency of lead sulfate crystal dissolution is improved.

[0077] After completing the above repair procedures, the plate expansion operation is initiated: the first voltage of the power frequency high-voltage generator 11 is increased to 12kV to generate the critical voltage of the high-voltage corona, and the first frequency is maintained at 50Hz. The high-voltage corona is used to discharge and carbonize the electrolyte fiber cotton inside the battery. The fiber cotton near the plate, accounting for about 6% of the total fiber cotton, transforms from cellulose structure into activated carbon under the action of the high-voltage corona, tightly adhering to the plate surface and becoming part of the plate. Because the electrolyte fiber cotton has a 12% volume redundancy in its design, the carbonized fiber cotton does not reduce the electrolyte storage capacity, but instead brings three effects: first, the activated carbon forms a protective layer, hindering the redeposition of lead sulfate ions and delaying plate sulfation; second, the specific surface area of ​​activated carbon reaches 1200m² / g, significantly expanding the plate reaction area, increasing it by more than 30% compared to the original plate area; and third, a graphene-like porous structure is formed, improving ion exchange efficiency.

[0078] Example 2: Implementation of voltage regulation during startup

[0079] This embodiment 2 focuses on voltage regulation during the startup phase of a 12V / 80Ah fiber lead-acid gel battery 1, involving two operating conditions. The specific process is as follows:

[0080] Based on the nominal specifications of the 12V / 80Ah battery, the preset start-up time is 8 minutes, during which the voltage needs to rise from the initial value to the target voltage of 15V for the high-temperature repair process. The initial voltage is set at 12.8V, which is 1.07 times the battery's nominal voltage, to avoid excessive initial voltage impacting the plates. The target voltage is set at 15V to meet the electric field requirements for lead sulfate crystal dissolution during the high-temperature repair process. A reference capacity of 20% of the battery's rated capacity (80Ah × 20% = 16Ah) is set to determine the degree of battery damage: a capacity loss of <16Ah indicates minor damage, and a capacity loss of ≥16Ah indicates severe damage. The curvature of the voltage rise curve is defined as follows: a curvature <0 indicates a concave curve with a gradual decrease in the rate of voltage rise; a curvature >0 indicates a convex curve with a gradual increase in the rate of voltage rise.

[0081] Using a lead-acid battery capacity tester, with the test current set to 0.2C (16A), which meets the requirements of the national standard GB / T18332.1-2019, the remaining capacity of batteries under two operating conditions was tested in a constant temperature environment of 25℃. The lost capacity was calculated based on the rated capacity.

[0082] Operating Condition 2-1: Slightly Damaged Battery Regulation

[0083] The rated capacity is 80Ah, and the remaining capacity is 70Ah. According to the formula: Loss capacity = Rated capacity - Remaining capacity, the loss capacity is 80Ah - 70Ah = 10Ah. Since 10Ah < 16Ah, it is judged as minor damage.

[0084] Start-up time period adjustment: The inverse correlation adjustment logic of "the greater the loss capacity, the shorter the start-up time period; the smaller the loss capacity, the longer the start-up time period" is adopted. The formula is: Adjusted start-up time period = base value + (|loss capacity - reference capacity| / rated capacity) × base value.

[0085] Calculation: Extension amplitude = (16Ah - 10Ah) / 80Ah × 8min = 0.075 × 8min = 0.6min; Adjusted start-up time = 8min + 0.6min = 8.6min.

[0086] Extended Case 2-1-1: If the remaining capacity of the battery is increased to 75Ah, with a capacity loss of 5Ah (less), then the extension = (16Ah - 5Ah) / 80Ah × 8min = 0.1375 × 8min = 1.1min. The adjusted start-up time = 8min + 1.1min = 9.1min. The smaller the capacity loss, the longer the start-up time. The purpose of extending the time is to protect the still intact active materials of the plates in the mildly aged battery, such as lead dioxide particles, through a smoother voltage rise, avoiding detachment caused by excessive voltage impact.

[0087] Increase curve curvature adjustment: Due to the capacity loss of 10Ah < 16Ah, a concave curve with curvature < 0 is adopted, and the voltage rise rate gradually slows down. The total duration is 8.6 minutes. Specific voltage change nodes:

[0088] In the first 4 minutes: the voltage rose from 12.8V to 14.0V at a rate of 0.3V / min.

[0089] In the last 4.6 minutes: the voltage rose from 14.0V to 15.0V at a rate of approximately 0.217V / min, which slowed down and coincided with a curvature of <0.

[0090] Adjustment objective: For mildly damaged battery plates, there is less sulfation and crystallization. A gradual voltage rise can avoid excessive local corona discharge. If the voltage rises rapidly in the initial stage, it can easily lead to premature carbonization of the fiber cotton, affecting subsequent capacity expansion. Precise control of the repair intensity is necessary.

[0091] Operating Condition 2-2: Severely Damaged Battery Regulation

[0092] With a rated capacity of 80Ah and a remaining capacity of 50Ah, the calculated loss capacity is 80Ah - 50Ah = 30Ah. Since 30Ah ≥ 16Ah, the damage is classified as severe.

[0093] Start-up time period adjustment: The inverse correlation adjustment logic is adopted. The formula is: Adjusted start-up time period = base value - (|loss capacity - reference capacity| / rated capacity) × base value.

[0094] Calculation: Shortening range = (30Ah - 16Ah) / 80Ah × 8min = 0.175 × 8min = 1.4min; Adjusted start-up time = 8min - 1.4min = 6.6min.

[0095] Extended Case 2-2-1: If the remaining capacity of the battery drops to 45Ah, with a capacity loss of 35Ah (or more), then the reduction in time = (35Ah - 16Ah) / 80Ah × 8min = 0.2375 × 8min = 1.9min. The adjusted start-up time = 8min - 1.9min = 6.1min. The greater the capacity loss, the shorter the start-up time. The purpose of shortening the time is to quickly raise the voltage to the effective repair threshold, reducing the ineffective reactions of severely aged batteries at low voltage levels. For example, at low voltage, the dissolution rate of lead sulfate crystals is only 30% of the target voltage, and prolonged low voltage can easily lead to plate passivation.

[0096] Increase curve curvature adjustment: Due to the capacity loss of 30Ah ≥ 16Ah, a convex curve with curvature > 0 is adopted, and the voltage rise rate gradually increases, with a total duration of 6.6 minutes. Specific voltage change nodes:

[0097] In the first 3 minutes: the voltage rose from 12.8V to 13.2V at a rate of approximately 0.133V / min;

[0098] In the last 3.6 minutes: the voltage rose from 13.2V to 15.0V at a rate of 0.5V / min, which is faster and conforms to the curvature > 0.

[0099] Extended Case 2-2-2: If another severely damaged battery loses 40Ah of capacity (more severe than 30Ah), the rate of increase in the latter part of the convex curve can be increased to 0.6V / min (faster than 0.5V / min). For example, if it rises from 13.2V to 15.1V in the last 3.2 minutes, it can ensure that the repair threshold is reached more quickly to deal with a thicker lead sulfate crystal layer.

[0100] To ensure precise voltage regulation, a dual protection mechanism is in place:

[0101] Voltage deviation correction: The actual voltage is compared with the preset curve in real time. If the deviation exceeds ±0.15V, such as the voltage of 14.0V in the preset 4min working condition 2-1, the actual measured voltage is 14.2V, with a deviation of +0.2V. Then, the voltage adjustment module of the power frequency high voltage generator 11 will correct the deviation by 0.05V / 10s until the deviation returns to within ±0.15V.

[0102] Temperature anomaly protection: The temperature is monitored in real time by a temperature sensor attached to the battery casing. If the temperature exceeds 43°C, such as when the temperature reaches 45°C during the rapid voltage rise in operating condition 2-2, the voltage rise will be stopped immediately and the current voltage will be maintained until the temperature drops below 40°C to avoid the active material of the plate from sintering due to high temperature.

[0103] Example 3: Implementation of increasing curve curvature based on temperature rise rate adjustment during the start-up phase.

[0104] This embodiment 3 takes a 12V / 100Ah fiber lead-acid gel battery 1 as an example, sets up two operating conditions, and elaborates in detail the implementation process of increasing the curvature of the curve based on the temperature rise rate adjustment during the start-up phase:

[0105] Key parameters for the preset startup phase are as follows: the temperature rise rate calculation cycle is set to 30 seconds, with real-time temperature values ​​collected every 30 seconds, and the ratio of the temperature difference between two adjacent values ​​to time is calculated; the curvature adjustment range is ±0.05 to ensure a smooth transition in the voltage rise trend and avoid abrupt changes; the temperature safety threshold is set to 45℃, exceeding which triggers the protection mechanism. The reference capacity is 20% of the rated capacity, i.e., 20Ah; the base startup time period is 10 minutes; the initial voltage value is 13V, and the target voltage value is 15V.

[0106] Two PT100 high-precision temperature sensors are installed on the side walls of the liquid storage tank, close to the center of the battery plates. The sensor data is uploaded to the control system in real time via a wireless transmission module. The average value of the two sensors is taken as the real-time temperature value to reduce the impact of local temperature deviation. At the same time, a voltage monitoring module is installed at the output of the power frequency high voltage generator 11 to record the first voltage change curve in real time.

[0107] After voltage regulation is activated, the control system collects real-time temperature values ​​in 30-second cycles. The temperature rise rate per minute (unit: ℃ / min) is calculated according to the formula "temperature rise rate = (current real-time temperature value - previous cycle real-time temperature value) / 30s × 60s / min".

[0108] Operating Condition 3-1: Slightly Damaged Battery Adjustment (Capacity Loss < Reference Capacity)

[0109] Basic data: Rated capacity 100Ah, remaining capacity 85Ah, lost capacity 15Ah, 15Ah < 20Ah, judged as minor damage.

[0110] Example of temperature rise rate calculation:

[0111] First 30 seconds: Real-time temperature 32.5℃; Second 30 seconds: Real-time temperature 33.1℃; Temperature rise rate = (33.1℃ - 32.5℃) / 0.5min = 1.2℃ / min;

[0112] Subsequent calculations yielded dynamic data: the temperature rise rate was 1.5℃ / min in the third 30 seconds and 0.9℃ / min in the fourth 30 seconds.

[0113] Adjustment logic: For minor damage, an inverse correlation adjustment is adopted (the faster the temperature rise rate, the greater the curvature; the slower the temperature rise rate, the smaller the curvature). The initial increase curve curvature is set to -0.1, which is a concave curve, in line with the initial smooth pressure rise requirement for minor damage.

[0114] Case 3-1-1: The accelerated temperature rise rate (from 1.2℃ / min to 1.8℃ / min) indicates an intensified thermal reaction in the battery. If the original curvature is maintained, the voltage rise rate may lead to a sudden increase in local temperature. Following the adjustment logic, the curvature was adjusted from -0.1 to -0.05. The increased curvature resulted in a smoother curve, and the voltage rise rate decreased from 0.3V / min to 0.2V / min. The effect after adjustment: The temperature rise rate decreased to 1.5℃ / min within the next 30 seconds, preventing the temperature from exceeding the safety threshold, and no signs of sintering were observed in the active materials of the electrode plates (such as lead dioxide particles).

[0115] Case 3-1-2: The slower rate of temperature rise (from 1.5℃ / min to 0.8℃ / min) indicates a stable battery thermal response with no risk of overheating. Following the adjustment logic, the curvature was changed from -0.05 to -0.15. The reduced curvature slightly accelerated the rate of temperature rise, increasing the voltage rise rate from 0.2V / min to 0.25V / min. The effect after adjustment: While ensuring thermal safety, the ineffective low-voltage reaction time was reduced, and the initial dissolution efficiency of lead sulfate crystals was improved by 10%.

[0116] Operating Condition 3-2: Severely Damaged Battery Adjustment (Lost Capacity > Reference Capacity)

[0117] Basic data: Rated capacity 100Ah, remaining capacity 60Ah, lost capacity 40Ah, 40Ah > 20Ah, judged as severe damage.

[0118] Example of temperature rise rate calculation:

[0119] First 30 seconds: Real-time temperature 31.8℃; Second 30 seconds: Real-time temperature 32.7℃; Temperature rise rate = (32.7℃ - 31.8℃) / 0.5min = 1.8℃ / min;

[0120] Subsequent calculations yielded dynamic data: 2.1℃ / min, 1.4℃ / min, etc.

[0121] Adjustment logic: For severe damage, positive correlation adjustment is adopted. The faster the temperature rise rate, the smaller the curvature; the slower the temperature rise rate, the larger the curvature. The initial increase curve curvature is set to 0.1, which is a convex curve, which meets the accelerated pressure rise requirement in the later stage of severe damage.

[0122] Case 3-2-1: The accelerated temperature rise rate (from 1.4℃ / min to 2.2℃ / min) indicates a significant thermal reaction in the battery. Continuing to accelerate the voltage increase (original curvature 0.1) could potentially damage the plates or cause uncontrolled carbonization of the fiber cotton. Following the adjustment logic, the curvature was changed from 0.1 to 0.03. The reduced curvature slowed the rate of voltage rise, decreasing the rate of voltage increase from 0.4V / min to 0.25V / min. The effect after adjustment: the temperature rise rate decreased to 1.7℃ / min within one minute, preventing the thermal reaction from compounding with voltage surges, and no burn marks appeared on the plates.

[0123] Case 3-2-2: The slower rate of temperature rise (from 2.0℃ / min to 1.3℃ / min) indicates a mild battery thermal response, providing conditions for faster voltage increase. Following the adjustment logic, the curvature was adjusted from 0.03 to 0.12. The increased curvature accelerated the rate of voltage rise, increasing the voltage rise rate from 0.25V / min to 0.45V / min. The effect after adjustment: the voltage quickly approached the target value of 15V, reaching it 1 minute earlier than planned. The thick lead sulfate crystal layer on the electrode surface began to loosen, laying the foundation for subsequent high-temperature repair.

[0124] To avoid delayed or excessive adjustments, a dual safeguard mechanism is established:

[0125] 1. Curvature adjustment range limit: Each curvature adjustment range shall not exceed ±0.05 to prevent voltage fluctuations caused by sudden changes in the curve. If no single curvature adjustment exceeds 0.05 in operating condition 3-1, the voltage change is smooth.

[0126] 2. Temperature Interlock Protection: If any temperature sensor detects a temperature exceeding 45℃, regardless of the current temperature rise rate and curvature, curvature adjustment will be immediately paused, and the current voltage will be maintained until the temperature drops below 42℃ before resuming adjustment. In operating condition 3-2, the protection was triggered due to a sudden increase in the temperature rise rate to 2.3℃ / min. After 30 seconds, the temperature dropped back to 43℃, and normal adjustment resumed.

[0127] Example 4: Start-up phase based on sinusoidal wave control current and dynamic frequency adjustment

[0128] This embodiment 4 uses a 12V / 100Ah fiber lead-acid gel battery 1 as the implementation object, sets up two operating conditions, and describes the specific steps of the start-up phase based on sinusoidal wave control of current and dynamic frequency adjustment:

[0129] Based on the plate characteristics of a 12V / 100Ah battery, the preset sinusoidal curve expression for the first current is I(t) = 2sin(2πft), where I(t) is the real-time current value, f is the sinusoidal frequency, and t is time. This ensures that the current changes smoothly and periodically, avoiding sudden increases and decreases. In the initial stage, the frequency is set to f = 50Hz, the current change period is 0.02s, the peak current is 2A, the valley current is 0A, and the average current is 1A. This satisfies the initial repair energy requirements while avoiding impact on the aging plates.

[0130] A preset curve is generated by the sine wave signal module of the power frequency high-voltage generator 11 and transmitted to the battery plates via the high-resistance high-voltage cable 13. Simultaneously, a Hall current sensor is connected in series in the cable circuit to collect the first current value in real time and upload it to the control system. The deviation between the actual current and the preset curve is compared. If the deviation exceeds ±0.05A, the output is immediately corrected through the signal module. For example, in the first minute of operation 4-1, the actual peak current is 2.02A with a deviation of 0.02A, requiring no correction. In the third minute, the actual peak current is 1.97A with a deviation of -0.03A, and the system automatically adjusts the output signal gain by 0.15% to bring the peak value back to 2.0A.

[0131] During the startup phase, data is collected at 1-minute intervals. The capacity ratio (capacity ratio = lost capacity / reference capacity, where the reference capacity is 20% of the rated capacity, i.e., 20Ah) and the temperature rise ratio (temperature rise ratio = real-time temperature rise rate / reference temperature rise rate, where the reference temperature rise rate is 1.5℃ / min) are calculated. Then, the comprehensive parameters are calculated using the formula "battery attribute ratio = capacity ratio × temperature rise ratio". Based on the positive correlation logic that "the larger the battery attribute ratio, the higher the sine wave frequency; the smaller the battery attribute ratio, the lower the sine wave frequency", the frequency is adjusted. The adjustment range is set to 5Hz / time, and the frequency adjustment range is 40-60Hz. A frequency below 40Hz may lead to insufficient current, while a frequency above 60Hz may cause plate vibration.

[0132] Operating Condition 4-1: Moderately Damaged Battery Adjustment

[0133] Basic data: Rated capacity 100Ah, remaining capacity 75Ah, lost capacity 25Ah, capacity ratio = 25Ah / 20Ah = 1.25, ratio > 1, aging degree exceeds the reference level.

[0134] Example of temperature rise ratio calculation:

[0135] Minute 1-Minute 2: Temperature 32.0℃→33.8℃, real-time temperature rise rate 1.8℃ / min, temperature rise ratio = 1.8 / 1.5 = 1.2;

[0136] Minute 2-3: Temperature 33.8℃→35.0℃, real-time temperature rise rate 1.2℃ / min, temperature rise ratio = 1.2 / 1.5 = 0.8.

[0137] Frequency adjustment case:

[0138] Case 4-1-1: Battery attribute ratio increased (from 1.0 to 1.5). In the first 1-2 minutes, the battery attribute ratio = 1.25 × 1.2 = 1.5 (relatively high). Following the positive correlation logic, the sine wave frequency was increased from the initial 50Hz to 55Hz. The effect after adjustment: the current change period was shortened to 0.018s, the number of times the current interacted with the plates per unit time increased, and the initial dissolution rate of lead sulfate crystals increased from 0.5mg / min to 0.7mg / min; simultaneously, the increased frequency promoted heat dissipation, and the subsequent temperature rise rate decreased to 1.2℃ / min, preventing overheating due to thermal accumulation.

[0139] Case 4-1-2: Battery property ratio decreases (from 1.5 to 1.0). In the 2nd-3rd minute, the battery property ratio = 1.25 × 0.8 = 1.0 (decreased from before). Following the positive correlation logic, the frequency is reduced from 55Hz to 50Hz. Effects after adjustment: The current change rate slows down, preventing excessive current from causing the active material at the electrode edge to detach, reducing the detachment rate from 0.3% to 0.1%; simultaneously, the basic repair efficiency is maintained, with the crystallization dissolution rate stabilizing at 0.5 mg / min.

[0140] Operating Condition 4-2: Slightly Damaged Battery Adjustment

[0141] Basic data: Rated capacity 100Ah, remaining capacity 90Ah, lost capacity 10Ah, capacity ratio = 10Ah / 20Ah = 0.5, ratio < 1, aging degree is lower than the reference level.

[0142] Example of temperature rise ratio calculation:

[0143] Minute 1-Minute 2: Temperature 31.5℃→32.7℃, real-time temperature rise rate 1.2℃ / min, temperature rise ratio = 1.2 / 1.5 = 0.8;

[0144] Minute 2-3: Temperature 32.7℃→33.9℃, real-time temperature rise rate 1.2℃ / min, temperature rise ratio = 0.8, remained stable.

[0145] Frequency adjustment case:

[0146] Case 4-2-1: Battery attribute ratio stabilizes at 0.4. In the first 3 minutes, the battery attribute ratio is 0.5 × 0.8 = 0.4 (relatively low). Following positive correlation logic, the frequency is reduced from 50Hz to 45Hz. The effect after adjustment: the current change cycle is extended to 0.022s, acting gently on the plates and avoiding minor damage to the battery caused by high-frequency current impact leading to active material loss, with the loss rate controlled below 0.05%; simultaneously, the temperature rise rate stabilizes at 1.2℃ / min, resulting in thermal stability.

[0147] Case 4-2-2: Battery property ratio slightly increased (from 0.4 to 0.5). In the 3rd-4th minute, the temperature rise rate increased to 1.5℃ / min (temperature rise ratio = 1.0), and the battery property ratio = 0.5 × 1.0 = 0.5 (slight increase). Following the positive correlation logic, the frequency was increased from 45Hz to 47.5Hz (due to the small increase in the ratio, the adjustment range was halved to 2.5Hz). The effect after adjustment: While ensuring thermal safety, a slight increase in current intensity increased the crystallization dissolution rate from 0.3mg / min to 0.4mg / min, avoiding an excessive decrease in repair efficiency.

[0148] Additional safeguards during the adjustment process:

[0149] 1. Peak current limit: Regardless of the frequency adjustment, the peak current of the sine wave is always limited to 1.5-2.5A by the control system. Below 1.5A, the repair efficiency is insufficient, and above 2.5A, it is easy to cause excessive heating of the plate. For example, when the frequency of operating condition 4-1 rises to 55Hz, the peak value is still maintained at 2A.

[0150] 2. Abnormal alarm protection: If the battery attribute ratio suddenly exceeds 2.0, such as in operating condition 4-1 where the temperature rise ratio suddenly rises to 2.0 due to a temperature sensor malfunction, and the attribute ratio reaches 2.5, an alarm will be triggered immediately, frequency adjustment will be paused and the current parameters will be maintained. At the same time, the backup temperature sensor will be started to re-collect data. Adjustment will be resumed after the fault is eliminated to avoid damage to the battery due to misoperation.

[0151] Example 5: Vibration repair process implemented by adjusting frequency based on vibration attenuation value

[0152] This embodiment 5 uses the vibration repair process of a 12V / 80Ah fiber lead-acid gel battery 1 as the implementation object, and illustrates the specific steps of adjusting the frequency based on the vibration attenuation value:

[0153] The preset target vibration value for ultrasonic vibration is 40μm, suitable for the sulfation and crystallization breaking requirements of this battery model. Three piezoelectric vibration sensors are deployed, installed on the front (close to the positive plate area), side (close to the center of the plate), and bottom (close to the negative plate area) of the battery, respectively. The initial output sine wave frequency of the high-frequency ultrasonic power supply 10 is 30kHz. The adjustment logic is "the greater the vibration attenuation value, the lower the frequency; the smaller the vibration attenuation value, the higher the frequency." The adjustment amplitude is set to 2kHz / cycle, and the frequency adjustment range is 20-40kHz. Below 20kHz, the vibration energy is insufficient, and above 40kHz, it is easy to cause mechanical damage to the plate.

[0154] Step 1: Vibration Data Acquisition and Calibration

[0155] Before installation, the three vibration sensors were uniformly calibrated, and standard vibration values ​​of 20μm, 40μm, and 60μm were output through a standard vibration table to ensure that the measurement error is ≤0.1μm. During installation, high-temperature resistant silicone was used to tightly attach the sensors to the battery housing, and a 0.5mm thick heat insulation pad was attached between the sensors and the housing to prevent the battery temperature from affecting the sensor accuracy. The temperature of the vibration repair process was controlled at 50-60℃, and the sensor operating temperature was stabilized at 25-30℃ after heat insulation.

[0156] After the high-frequency ultrasonic power supply 10 is turned on, the sensor collects vibration data at 100ms intervals and transmits it to the control system in real time via RS485 bus. Abnormal data is removed during the acquisition process. If the deviation between a single acquired value and the average of two adjacent values ​​exceeds 5μm, it is identified as interference data and replaced with the adjacent average value. For example:

[0157] Case 5-1-1: In the first second after startup, the values ​​collected by the three sensors were 32.1μm, 31.8μm, and 32.3μm, respectively, with no abnormal data;

[0158] Case 5-1-2: 5 seconds after startup, the value collected by the front sensor suddenly changed to 10.2μm, which deviated from the adjacent average value of 31.9μm by 21.7μm. This was determined to be interference, and the value was replaced with 31.9μm.

[0159] Step 2: Calculation of real-time vibration value and vibration attenuation value

[0160] 1. Real-time vibration value calculation: The weighted average method is adopted (bottom surface weight 0.4, front and side surface weights 0.3 each), and the formula is "real-time vibration value = front sensor value × 0.3 + side sensor value × 0.3 + bottom sensor value × 0.4".

[0161] Case 5-2-1 (relatively sufficient vibration energy): front 38.2μm, side 37.9μm, bottom 39.1μm, real-time vibration value = 38.2×0.3+37.9×0.3+39.1×0.4=38.47μm≈38.5μm;

[0162] Case 5-2-2 (high vibration energy loss): front 29.5μm, side 28.8μm, bottom 30.2μm, real-time vibration value = 29.5×0.3+28.8×0.3+30.2×0.4=29.57μm≈29.6μm.

[0163] 2. Vibration attenuation value calculation: The formula is "Vibration attenuation value = target vibration value - real-time vibration value" (when the real-time vibration value exceeds the target value, the attenuation value is 0).

[0164] Case 5-2-1: Vibration attenuation value = 40μm - 38.5μm = 1.5μm (small attenuation value, less energy loss);

[0165] Case 5-2-2: Vibration attenuation value = 40μm - 29.6μm = 10.4μm (large attenuation value means more energy loss).

[0166] Step 3: Adjust the frequency based on the vibration attenuation value

[0167] Case 5-3-1: Small vibration attenuation value (1.5μm) → increased frequency. The initial frequency was 30kHz. Due to the small vibration attenuation value of 1.5μm, the frequency was increased to 32kHz according to the adjustment logic. The effect after adjustment: After 10s, the real-time vibration value = 39.8×0.3 + 39.5×0.3 + 40.3×0.4 ≈ 40μm, and the vibration attenuation value dropped to 0μm, reaching the target vibration state; the sulfate crystal crushing efficiency remained above 90%, and microscopic observation showed that the diameter of the crystal particles on the electrode surface decreased from 5μm to below 1μm.

[0168] Case 5-3-2: Large vibration attenuation value (10.4μm) → frequency reduction. The initial frequency was 30kHz. Due to the relatively large vibration attenuation value of 10.4μm, the frequency was reduced to 28kHz according to the adjustment logic. The effect after adjustment: After 15s, the real-time vibration value = 35.2×0.3 + 34.8×0.3 + 36.1×0.4 ≈ 35.4μm, and the vibration attenuation value decreased to 4.6μm; further reducing to 26kHz, after 20s, the real-time vibration value increased to 38.2μm, with an attenuation value of only 1.8μm, and the crystal removal rate increased from 60% to 85%.

[0169] Boundary Case 5-3-3: Vibration attenuation value is 0 (real-time vibration value = 40μm). For example, front 40.1μm, side 39.9μm, bottom 40.0μm, real-time vibration value = 40.0μm, vibration attenuation value = 0μm, maintain the current frequency (e.g. 32kHz) unchanged, and ensure that the vibration intensity is stable within the target range.

[0170] Additional safeguards during the regulation process:

[0171] 1. Over-vibration protection: If the real-time vibration value exceeds 45μm (1.125 times the target value), the frequency will be immediately reduced by 5kHz regardless of the attenuation value. For example, if the frequency rises to 34kHz after a certain adjustment and the real-time vibration value reaches 46.2μm, the system will automatically reduce to 29kHz, and the vibration value will drop back to 41.5μm after 10s.

[0172] 2. Sensor Failure Switching: If any sensor fails, such as the side sensor having no data output, it will automatically switch to a dual-sensor weighted average (front side weight 0.5, bottom side weight 0.5). If the side sensor fails, the front side will be 38.5μm and the bottom side will be 39.2μm. The real-time vibration value = 38.5×0.5 + 39.2×0.5 = 38.85μm, with the error controlled within 1%.

[0173] Example 6: Implementation of current amplitude adjustment based on vibration change rate during ultrasonic vibration start-up phase

[0174] This embodiment 6 uses the ultrasonic vibration start-up phase of a 12V / 80Ah fiber lead-acid gel battery 1 as the implementation object, and describes the specific steps of adjusting the maximum amplitude of the first current based on the vibration change rate:

[0175] The preset start-up time is 120 seconds to accommodate the transition requirements of the vibration system from start-up to stability. The target vibration value of the ultrasonic vibration is 40 μm. The initial maximum amplitude of the first current is set to 3A (peak value of the sine wave current, valley value is 0A). Three piezoelectric vibration sensors are deployed (same as in Example 5, installed on the front, side, and bottom of the battery). The initial frequency of the sine wave curve output by the high-frequency ultrasonic power supply 10 is 30kHz. The adjustment logic is "the greater the vibration change speed, the smaller the maximum amplitude; the smaller the vibration change speed, the larger the maximum amplitude." The adjustment amplitude is set to 0.3A / cycle, and the maximum amplitude adjustment range is 1.5-3.5A. Below 1.5A, the driving energy is insufficient, and above 3.5A, the transducer is prone to overheating.

[0176] Step 1: Calculation of vibration attenuation value and vibration rate of change

[0177] 1. Vibration Attenuation Calculation: During the startup phase, vibration data from three sensors are collected at 500ms intervals. A weighted average method (0.3 for front, 0.3 for side, and 0.4 for bottom) is used to calculate the real-time vibration value. Then, the attenuation value is calculated according to the formula: "Vibration Attenuation = Target Vibration Value - Real-time Vibration Value" (the attenuation value is 0 if the real-time vibration value exceeds the target value). Example:

[0178] First cycle (0-500ms): Real-time vibration value 28.5μm, vibration attenuation value = 40-28.5=11.5μm;

[0179] Second cycle (500-1000ms): Real-time vibration value 31.2μm, vibration attenuation value = 40-31.2=8.8μm;

[0180] Third cycle (1000-1500ms): Real-time vibration value 33.8μm, vibration attenuation value = 40-33.8=6.2μm.

[0181] 2. Calculation of Vibration Change Rate: The formula is "Vibration Change Rate = (Current Cycle Vibration Decay Value - Previous Cycle Vibration Decay Value) / Cycle Duration (0.5s)" (A negative result indicates a decrease in decay value and slower energy loss; a positive result indicates an increase in decay value and accelerated energy loss). Example:

[0182] The second cycle relative to the first cycle: vibration change rate = (8.8-11.5) / 0.5 = -5.4μm / s (negative value, the attenuation value decreases, and energy loss slows down).

[0183] The vibration rate of the third period relative to the second period is (6.2-8.8) / 0.5 = -5.2 μm / s (a negative value, indicating a continuous decrease in attenuation).

[0184] Abnormal example: The decay value in the 5th cycle is 7.5μm and the decay value in the 6th cycle is 8.3μm. The vibration change rate = (8.3-7.5) / 0.5 = 1.6μm / s (positive value, energy loss is aggravated).

[0185] To avoid interference from instantaneous fluctuations, the vibration rate is processed using a moving average method, taking the average of the rates of change over three adjacent periods. For example, the moving average rate of change in the third period = (-5.4 - 5.2 + rate of change in the fourth period) / 3, ensuring that the data reflects the true decay trend.

[0186] Step 2: Adjust the maximum amplitude of the first current based on the vibration change rate.

[0187] The adjustment cycle for the first maximum current amplitude is synchronized with the calculation cycle for the vibration rate change (500ms / cycle), with an initial maximum amplitude of 3A. A specific adjustment example is as follows:

[0188] Case 6-2-1: Larger vibration rate (increased energy loss) → smaller maximum amplitude

[0189] Energy loss tends to increase during the 8th-10th cycles (4-5 seconds) after startup:

[0190] 8th cycle (3500-4000ms): Vibration attenuation value 5.1μm;

[0191] 9th cycle (4000-4500ms): Vibration attenuation value 6.3μm, vibration change rate = (6.3-5.1) / 0.5 = 2.4μm / s (positive value, change rate > preset threshold 1.0μm / s, energy loss is aggravated).

[0192] According to the adjustment logic, the maximum amplitude of the first current will be reduced by 0.3A from the current 2.7A to 2.4A.

[0193] Effects after adjustment: The current driving intensity is reduced, the over-driving of the vibration system is alleviated, the vibration attenuation value in the 10th cycle (4500-5000ms) drops to 5.8μm, the vibration change rate = (5.8-6.3) / 0.5 = -1.0μm / s, and the energy loss is reduced; microscopic observation shows that there are no cracks at the edge of the electrode plate, avoiding mechanical damage.

[0194] Case 6-2-2: Small vibration rate (gradual energy loss) → Increased maximum amplitude

[0195] Energy loss tends to level off during cycles 20-22 (10-11s) after startup.

[0196] 20th cycle (9500-10000ms): Vibration attenuation value 2.3μm;

[0197] 21st cycle (10000-10500ms): vibration decay value 2.1μm, vibration change rate = (2.1-2.3) / 0.5 = -0.4μm / s (absolute value < threshold 0.8μm / s, energy loss is gradual).

[0198] According to the adjustment logic, the maximum amplitude of the first current will be increased by 0.3A from the current 2.1A to 2.4A.

[0199] Effects after adjustment: The current-driven energy is enhanced, the vibration output of the ultrasonic transducer 9 is stable, the vibration attenuation value in the 22nd cycle (10500-11000ms) is reduced to 1.8μm, and the real-time vibration value is increased to 38.2μm (close to the target value); the sulfate crystal crushing efficiency is increased from 75% to 85% (by sampling and detection of residual crystals on the electrode surface).

[0200] Case 6-2-3: Vibration rate of change approaches 0 (energy loss stabilizes) → Maximum amplitude maintained

[0201] Energy loss stabilized during cycles 35-38 (17.5-19s) after startup.

[0202] 35th cycle (17000-17500ms): Vibration attenuation value 1.2μm;

[0203] 36th cycle (17500-18000ms): vibration decay value 1.1μm, vibration change rate = (1.1-1.2) / 0.5 = -0.2μm / s (the change rate is extremely small).

[0204] At this point, the maximum amplitude of the first current of 2.4A is kept constant to avoid vibration fluctuations caused by adjustment.

[0205] Effects after adjustment: The subsequent periodic vibration attenuation value stabilized at 1.0-1.2μm, and the real-time vibration value was 38.8-39.0μm. The vibration system entered a stable state, laying the foundation for the formal repair process.

[0206] Additional safeguards during the regulation process:

[0207] 1. Temperature Interlock Protection: A temperature sensor is installed on the battery casing. If the temperature exceeds 60℃ during startup, the upper temperature limit for the vibration repair process will be immediately reduced by 0.5A, regardless of the vibration rate, until the temperature drops below 55℃. For example, if the temperature rises to 61.2℃ after an adjustment, the amplitude will decrease from 2.4A to 1.9A, and the temperature will drop back to 58.5℃ after 30 seconds.

[0208] 2. Abnormal alarm mechanism: If the absolute value of the vibration change velocity exceeds 3.0μm / s for three consecutive cycles, such as 3.2μm / s, 3.5μm / s, and 3.3μm / s consecutively, it is determined that the vibration system is abnormal. The amplitude adjustment is paused and the current parameters are maintained. At the same time, an alarm is triggered to check for sensor or transducer failures and avoid battery damage.

[0209] Example 7: Implementation of Plate Capacity Expansion System and Storage Medium

[0210] Embodiment 7 of this application discloses a plate capacity expansion system for a fiber lead-acid gel battery, including a processor, wherein the processor executes the steps of the plate capacity expansion method for a fiber lead-acid gel battery as described in any one of Embodiments 1-6.

[0211] The system hardware architecture needs to be adapted to the requirements of each process:

[0212] High-voltage power supply module: Selects a power frequency high-voltage generator 11 with an output voltage of 0-15kV and a current of 0-5A, which supports real-time adjustment of AC parameters (voltage, current, frequency);

[0213] Temperature control module: integrates PT100 temperature sensor (measurement range -20-100℃, accuracy ±0.1℃) and microwave DC power supply 7 (output power 0-1000W) to achieve precise temperature control in high-temperature repair processes;

[0214] Vibration control module: Equipped with a high-frequency ultrasonic power supply 10 (output frequency 20-40kHz, power 0-500W) and a piezoelectric vibration sensor (measurement range 0-100μm) to ensure energy stability in the vibration repair process;

[0215] Data processing module: Adopts industrial-grade processor (such as ARM Cortex-A9), supports temperature and vibration data acquisition and parameter adjustment calculation within 100ms, ensuring the speed of process coordination response.

[0216] Embodiment 7 of this application also discloses a storage medium storing a program, which, when executed by a processor, implements the steps of the plate expansion method for fiber lead-acid gel batteries described in any one of Embodiments 1-6.

[0217] Storage media can be SD card, USB flash drive, or industrial hard drive (storage capacity ≥ 1GB). The program must include the following core modules:

[0218] Initialization module: Automatically reads basic parameters such as battery rated capacity and reference capacity, and configures initial parameters for each process, such as first voltage 14V, first current 1.5A, and target vibration value 40μm;

[0219] Process control module: It realizes the logic control of high temperature repair, vibration repair and collaborative processes respectively, including parameter adjustment algorithms, such as temperature inverse correlation adjustment of current and vibration attenuation value inverse correlation adjustment of frequency;

[0220] Protection module: Built-in alarm and emergency handling procedures for temperature over-threshold (e.g., 45℃) and vibration over-threshold (e.g., 45μm) to prevent battery damage;

[0221] Data recording module: Stores temperature, vibration, voltage, and current data in real time during the repair process (sampling frequency 1 time / 10s), supporting subsequent traceability of repair effects and parameter optimization.

[0222] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A method of expanding the capacity of the plates of a fibrous lead acid gel battery, characterized in that, The method comprises the following steps: placing the fiber lead-acid gel battery (1) into the liquid storage tank (2) containing the conductive liquid (12), so that the conductive liquid (12) is immersed into the top cover of the fiber lead-acid gel battery (1); in the repair process of the fiber lead-acid gel battery (1), a first alternating current is applied to the two plates of the fiber lead-acid gel battery (1) based on a high-voltage generator, the voltage of the first alternating current is a first voltage, the current of the first alternating current is a first current, and the frequency of the first alternating current is a first frequency; the repair process comprises a high-temperature repair process and a vibration repair process; in the time period when the high-temperature repair process is independently executed, the real-time temperature value of the fiber lead-acid gel battery (1) is obtained, and the first current is inversely related to the real-time temperature value, that is, the lower the real-time temperature value, the greater the first current, and the higher the real-time temperature value, the smaller the first current; in the time period when the vibration repair process is independently executed, the real-time vibration value of the fiber lead-acid gel battery (1) is obtained, and the first frequency is inversely related to the real-time vibration value, that is, the greater the real-time vibration value, the lower the first frequency, and the smaller the real-time vibration value, the higher the first frequency; in the time period when the high-temperature repair process and the vibration repair process are simultaneously executed, the adjustment step of the first frequency is positively related to the temperature rise speed of the real-time temperature value, that is, the faster the temperature rise speed, the greater the adjustment step of the first frequency, and the slower the temperature rise speed, the smaller the adjustment step of the first frequency; the adjustment step of the first current is inversely related to the change speed of the real-time vibration value, that is, the faster the change speed, the smaller the adjustment step of the first current, and the slower the change speed, the greater the adjustment step of the first current; the vibration repair process comprises an ultrasonic vibration process, a plurality of vibration sensors are used to obtain vibration values, and the real-time vibration value is calculated based on the plurality of vibration values; a target vibration value of the ultrasonic vibration is obtained, a vibration attenuation value is calculated based on the target vibration value and the real-time vibration value, and a vibration change speed of the vibration attenuation value is calculated in the starting time period of the ultrasonic vibration; the maximum amplitude of the first current is inversely related to the vibration change speed, that is, the greater the vibration change speed, the smaller the maximum amplitude, and the smaller the vibration change speed, the greater the maximum amplitude.

2. The fibered lead acid gel battery plate expansion method according to claim 1, characterized in that, the value of the first voltage is gradually increased according to a preset increasing curve in a preset starting time period; the rated capacity and the residual capacity of the fiber lead-acid gel battery (1) are obtained, and the loss capacity is calculated based on the rated capacity and the residual capacity; the starting time period is inversely related to the loss capacity, that is, the greater the loss capacity, the shorter the starting time period, and the smaller the loss capacity, the longer the starting time period; if the loss capacity is less than a preset reference capacity, the curvature of the increasing curve is less than 0, otherwise, the curvature of the increasing curve is greater than 0.

3. The fibered lead acid gel battery plate expansion method according to claim 2, characterized in that, in the preset starting time period, the temperature rise speed is calculated based on the real-time temperature value; if the loss capacity is less than a preset reference capacity, the curvature of the increasing curve is inversely related to the temperature rise speed, that is, the faster the temperature rise speed, the greater the curvature, and the slower the temperature rise speed, the smaller the curvature; if the loss capacity is greater than a preset reference capacity, the curvature of the increasing curve is positively related to the temperature rise speed, that is, the faster the temperature rise speed, the smaller the curvature, and the slower the temperature rise speed, the greater the curvature.

4. The fibered lead acid gel battery plate expansion method according to claim 1, characterized in that, The high-temperature repairing process comprises a microwave heating process, which is based on a magnetron (3), a conical waveguide (5), a mica diffusion sheet (6) and a microwave direct-current power supply (7). The power supply end of the magnetron (3) is connected with a direct-current high-voltage cable (4) and then connected with the high-voltage direct-current output end of the microwave direct-current power supply (7). The signal output end of the magnetron (3) is connected with the conical waveguide (5) and then connected with one side of the mica diffusion sheet (6). The other side of the mica diffusion sheet (6) is tightly attached to one side surface of the fiber lead acid gel battery (1).

5. The method of claim 2, wherein the fibered lead acid gel battery plate expansion is characterized by, During the starting period, the first current is controlled according to a preset sinusoidal curve; The ratio of the loss capacity to the reference capacity is calculated as a capacity ratio; The ratio of the temperature rise speed to the preset reference speed is calculated as a temperature rise ratio; The battery attribute ratio is calculated according to the capacity ratio and the temperature rise ratio through a ratio algorithm; The frequency of the sinusoidal curve is adjusted according to the positive correlation of the battery attribute ratio. The larger the battery attribute ratio, the higher the frequency. The smaller the battery attribute ratio, the lower the frequency.

6. The method of claim 1, wherein the fibered lead acid gel battery plate expansion is characterized by, The ultrasonic vibration process is based on an ultrasonic diffusion plate (8), an ultrasonic transducer (9) and a high-frequency ultrasonic power supply (10). One side of the ultrasonic diffusion plate (8) is tightly attached to the bottom surface of the battery, and the other side of the ultrasonic diffusion plate (8) is connected with the ultrasonic signal output end of the ultrasonic transducer (9). The signal input end of the ultrasonic transducer (9) is connected with the signal output end of the high-frequency ultrasonic power supply (10).

7. The method of claim 6, wherein the fibered lead acid gel battery plate expansion is characterized by, The target vibration value of the ultrasonic vibration is obtained, the vibration attenuation value is calculated according to the target vibration value and the real-time vibration value, and the frequency of the sinusoidal curve is adjusted according to the inverse correlation of the vibration attenuation value. The larger the vibration attenuation value, the lower the frequency. The smaller the vibration attenuation value, the higher the frequency.

8. A fibered lead acid gel battery's plates expansion system characterized in that, The processor executes the steps of the fiber lead acid gel battery plate capacity expansion method according to any one of claims 1-7.

9. A storage medium, characterized by The storage medium stores a program, and the program is executed by the processor to realize the steps of the fiber lead acid gel battery plate capacity expansion method according to any one of claims 1-7.

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