A method and system for managing dual battery cells in industrial mobile devices.

Abstract

This invention relates to the field of mobile computing devices and energy management technology, and particularly to a dual-battery cell management method and system for industrial mobile devices. The method includes the following steps: splitting the battery pack of the industrial mobile device into two independent cells, connecting them in parallel to an intelligent power management unit, and configuring each cell with a fast-charging circuit, so that each fast-charging circuit forms a dual-path independent closed-loop control path with an external power supply, the corresponding cell, and the intelligent power management unit. This invention, through parallel connection of dual cells, intelligent power management, and dual-path fast-charging control, combined with dynamic load balancing, fault isolation, and load-adaptive power supply strategies, achieves safe and efficient application of batteries in industrial mobile devices, thereby improving charging efficiency and battery life stability, and enhancing battery life and safety.

Description

Technical Field

[0001] This invention relates to the field of mobile computing devices and energy management technology, and in particular to a dual-battery cell management method and system for industrial mobile devices. Background Technology

[0002] In the field of industrial mobile equipment, scenarios involving extremely long-term offline operations such as field surveying, long-distance transportation, and emergency disaster relief have extremely high demands for equipment battery life. However, existing solutions for ultra-long battery life have significant drawbacks. While external power bank solutions are low-cost and readily available, they require a cable connection to an external power source. The additional equipment and cables severely reduce integration and portability, and cables are prone to detachment and damage during movement. Furthermore, charging efficiency is low due to limitations in power bank power and cable losses, potentially leading to "reverse charging" under high loads. Additionally, their independent operation from the internal charging and discharging management system results in poor coordination, posing risks of overcharging, over-discharging, and overheating in harsh environments. Simply increasing the capacity of a single battery achieves integration but faces multiple challenges: the massive heat generated during fast charging and high-current discharging of ultra-large single-cell batteries cannot be handled by ordinary cooling systems, easily leading to battery bulging, lifespan degradation, or even thermal runaway; large and heavy batteries place extremely high demands on the equipment's structural impact and drop resistance, and simply adding more components reduces reliability; moreover, charging a 30,000mAh battery with single-path fast charging takes several hours, resulting in a poor user experience. Summary of the Invention

[0003] Therefore, it is necessary to provide a dual-battery cell management method and system for industrial mobile devices to solve at least one of the above-mentioned technical problems.

[0004] To achieve the above objectives, a dual-battery cell management method for industrial mobile devices includes the following steps:

[0005] Step S1: The battery pack of the industrial mobile device is split into two independent cells and connected to the intelligent power management unit in parallel. Each cell is configured with a fast charging circuit, so that each fast charging circuit forms a dual independent closed-loop control path with the external power supply, the corresponding cell and the intelligent power management unit.

[0006] Step S2: Collect real-time operating data of the two cells and transmit it to the intelligent power management unit. At the same time, send control signals to the cell discharge circuit to perform dynamic load balancing or alternating main discharge switching on the two cells.

[0007] Step S3: Continuously monitor the operating data of the two cells. When the operating data of either cell exceeds the preset range, send a command to the circuit switch corresponding to that cell to perform single-circuit isolation and disconnection, while maintaining a stable connection between the other normal cell and the main circuit.

[0008] Step S4: When the industrial mobile device is connected to an external power source and the power supply meets the preset requirements, control the two fast charging circuits to start synchronously to perform parallel collaborative fast charging of the dual-cell batteries;

[0009] Step S5: When the industrial mobile device is in a discharging state and the load power is lower than the maximum discharge power of a single cell, control the single cell to perform main power output while the other cell remains in low-power standby mode.

[0010] The present invention also provides a dual-battery cell management system for industrial mobile devices, for executing the dual-battery cell management method for industrial mobile devices described above, the dual-battery cell management system for industrial mobile devices comprising:

[0011] The dual-cell parallel architecture module is used to split the battery pack of industrial mobile equipment into two independent cells, which are connected to the intelligent power management unit in parallel. Each cell is configured with a fast charging circuit, so that each fast charging circuit forms a dual independent closed-loop control path with the external power supply, the corresponding cell and the intelligent power management unit.

[0012] The dual-cell monitoring and control module is used to collect real-time operating data of the two cells and transmit it to the intelligent power management unit. At the same time, it sends control signals to the cell discharge circuit to perform dynamic load balancing or alternating main discharge switching on the two cells.

[0013] The dual-cell single-path isolation module is used to continuously monitor the operating data of two cells. When the operating data of either cell exceeds the preset range, a command is sent to the circuit switch corresponding to that cell to perform single-path isolation and disconnection, while maintaining a stable connection between the other normal cell and the main circuit.

[0014] The dual-cell parallel fast charging control module is used to control two fast charging circuits to start synchronously to perform parallel collaborative fast charging of the dual cells when the industrial mobile equipment is connected to an external power source and the power supply meets the preset requirements.

[0015] The dual-cell power supply mode switching module is used to control one cell to perform main power output and the other cell to remain in low-power standby mode when the industrial mobile equipment is in a discharging state and the load power is lower than the maximum discharge power of a single cell.

[0016] The beneficial effects of this invention are:

[0017] On the one hand, by splitting the battery pack of industrial mobile equipment into two independent cells and connecting them in parallel to the intelligent power management unit, and configuring a fast charging circuit for each cell, each fast charging circuit forms a dual-path independent closed-loop control path with the external power supply, the corresponding cell, and the intelligent power management unit. When the equipment is connected to an external power source and the power supply meets the preset requirements, the two fast charging circuits can be started simultaneously to perform parallel and coordinated fast charging of the two cells, significantly shortening the charging time of ultra-large capacity batteries. This avoids the impact of long charging times on work progress during high-intensity offline operations such as field surveying and emergency rescue, and quickly replenishes the power to ensure the continuity of operations.

[0018] On the other hand, the intelligent power management unit collects the operating data of the two cells in real time and sends control signals to the cell discharge circuit based on the data. It performs dynamic load balancing or alternating main discharge switching on the two cells to avoid a single cell operating under high load for a long time, effectively balancing the cell degradation rate and extending the overall battery pack life. At the same time, the system continuously monitors the cell operating data. When the operating data of any cell exceeds the preset range, it will immediately isolate and disconnect that cell, keeping only the other normal cell stably connected to the main circuit. This eliminates the safety hazards such as overcharging, over-discharging, and thermal runaway caused by single cell failure, improves the safety of the equipment in industrial scenarios such as long-distance transportation and harsh outdoor environments, and reduces the maintenance and replacement costs caused by battery failure.

[0019] On the other hand, during the equipment discharge phase, the system flexibly adjusts the power supply strategy according to the load power. When the load power is lower than the maximum discharge power of a single cell, the single cell is controlled to perform the main power output, while the other cell remains in low-power standby mode, avoiding energy waste caused by both cells working simultaneously and reducing unnecessary power consumption. In high-load scenarios, the power demand can be met through the coordinated discharge of the two cells, ensuring stable output of equipment performance. This refined discharge scheduling mechanism can fully leverage the advantages of the battery pack's ultra-large capacity and adapt to the endurance requirements of industrial mobile equipment under different operating intensities, ensuring continuous and stable power supply for the equipment during ultra-long offline operations of several days or even more than a week. Attached Figure Description

[0020] Figure 1 This is a flowchart illustrating the steps of a dual-battery cell management method for industrial mobile devices.

[0021] Figure 2 This is a schematic diagram of the core structure of the battery compartment;

[0022] Figure 3 This is a schematic diagram of a dual-unit intelligent management architecture;

[0023] Figure 4 This is a schematic diagram of the stepped load adjustment process curve;

[0024] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0025] The technical method of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0026] Furthermore, the accompanying drawings are merely illustrative of the invention and are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar parts, and therefore repeated descriptions of them will be omitted. Some block diagrams shown in the drawings are functional entities and do not necessarily correspond to physically or logically independent entities. These functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor methods and / or microcontroller methods.

[0027] It should be understood that although the terms "first," "second," etc., may be used herein to describe various units, these units should not be limited by these terms. These terms are used merely to distinguish one unit from another. For example, without departing from the scope of the exemplary embodiments, a first unit may be referred to as a second unit, and similarly, a second unit may be referred to as a first unit. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0028] To achieve the above objectives, please refer to Figures 1 to 4 A dual-battery cell management method for industrial mobile devices, integrating an intelligent power management unit, includes the following steps:

[0029] Preferably, step S1: the battery pack of the industrial mobile device is split into two independent cells and connected to the intelligent power management unit in parallel. Each cell is configured with a fast charging circuit, so that each fast charging circuit forms a dual independent closed-loop control path with the external power supply, the corresponding cell and the intelligent power management unit.

[0030] In this embodiment, a 30000mAh lithium-ion battery pack built into an industrial-grade ruggedized tablet PC is selected. Using a special tool, it is disassembled along a pre-designed split seam on the outer casing to obtain two independent 15000mAh lithium-ion cells. After disassembly, the positive and negative terminals of the cells are kept intact. Using 2.0mm² nickel-plated copper strips, the positive and negative terminals of the first cell are soldered to the BAT1+ and GND interfaces of the IPM-900 intelligent power management unit, respectively. The positive and negative terminals of the second cell are soldered to the BAT2+ and GND interfaces of the same unit, respectively. After soldering, the total parallel voltage is measured to be 3.8V±0.05V using a digital multimeter. Each cell is equipped with a PD-33W fast charging circuit. The input terminals of both fast charging circuits are connected to the 19V / 3.5A DC output terminal (output ripple coefficient ≤50mA) converted from an external 220V / 50Hz AC power supply by an AC-1206 AC-DC converter. The first fast charging circuit outputs positive and negative terminals are connected to the positive and negative terminals of the first battery cell, and the communication feedback pins (CC1, CC2) are connected to the CHG-CTRL1 interface of the IPM-900 hub. The second fast charging circuit outputs positive and negative terminals are connected to the positive and negative terminals of the second battery cell, and the communication feedback pin is connected to the CHG-CTRL2 interface of the hub. Through the built-in detection module of the IPM-900 hub, it is confirmed that the loop impedance of the first circuit (19V / 3.5A DC power supply terminal → first PD-33W circuit → first battery cell → IPM-900 hub → power supply terminal negative terminal) and the second circuit (19V / 3.5A DC power supply terminal → second PD-33W circuit → second battery cell → IPM-900 hub → power supply terminal negative terminal) is 0.3Ω±0.02Ω. The insulation resistance of both circuits is ≥100MΩ as measured by an IR-2000 insulation resistance tester, and there are no short circuits, loose connections or poor insulation.

[0031] It should be noted that the specific models of the special disassembly tools, digital multimeters, AC-DC converters, insulation resistance testers, nickel-plated copper strips, intelligent power management units, and fast charging circuits used in this embodiment are merely exemplary choices for implementing this step. This application does not limit the specific types or models of the above-mentioned equipment and tools, and the use of other equipment and tools that can achieve the same function is also acceptable.

[0032] Preferably, step S2: collect real-time operating data of the two cells and transmit it to the intelligent power management unit, and at the same time send control signals to the cell discharge circuit to perform dynamic load balancing distribution or alternating main discharge switching on the two cells.

[0033] Optionally, the real-time operating data of the two battery cells collected in step S2 are as follows:

[0034] Elastic detection contacts are deployed on the tabs and sidewalls of the positive and negative terminals of the two cells respectively. The elastic detection contacts have built-in miniature pressure sensors. Before data collection, the contact pressure is adjusted to a suitable contact state through sensor feedback.

[0035] After the pre-power-on stabilization signal is established, multiple sets of data are continuously collected for each parameter in the order of voltage, internal resistance, and temperature. The median value of each set of data is taken, extreme values ​​are removed, and the average value is calculated.

[0036] In one embodiment, four TC-F03 type elastic detection contacts are deployed on the tabs and sidewalls of the positive and negative electrodes of two independent 15000mAh lithium-ion cells (one for each positive and negative electrode and two for each sidewall). Each contact has a built-in MSP-01 type miniature pressure sensor. The sensor signal output terminal is connected to the P-SENSE1 to P-SENSE8 interfaces of the IPM-900 intelligent power management unit through shielded wires. Before data acquisition, the pressure data of each contact is obtained through the IPM-900 hub. When the pressure is below 0.8N, the contact extension is adjusted until the pressure stabilizes between 0.8N and 1.2N. Data is recorded every 50ms during the adjustment process, and the pressure fluctuation is ≤0.1N. A pre-power-on command is sent to the IPM-900 hub, and a 3.3V DC signal is output to the detection circuit through the internal voltage regulator module. The pre-power-on is performed for 10s. Data acquisition begins after the circuit current stabilizes at 5mA±0.2mA.

[0037] In another embodiment, data is collected in the order of voltage, internal resistance, and temperature. Voltage is collected through the V-CH1 and V-CH2 channels with 16-bit AD precision and a frequency of 10Hz, with 20 sets collected for each cell (range 3.2V-4.2V). Internal resistance is collected through the built-in AC impedance module of the hub (1kHz frequency, 100mA excitation current), with 20 sets collected for each cell (range 50mΩ-200mΩ). Temperature is collected through the built-in NTC thermistor of the contact (range -20℃-85℃, accuracy ±0.5℃), with 20 sets collected from each of the two contacts on the side wall of each cell. After collection, the extreme values ​​of the first 3 and last 3 digits of each parameter are removed, and the average value of the remaining 14 sets of data is calculated (voltage is retained to 2 decimal places, internal resistance is retained to 3 decimal places, and temperature is retained to 1 decimal place). The result is stored in the built-in storage unit of the IPM-900 hub at addresses 0x0020-0x005F.

[0038] Optionally, the transmission to the intelligent power management unit in step S2 specifically involves:

[0039] After acquisition, the voltage, internal resistance, and temperature data are marked in a time-division manner, and the acquisition timestamp and cell number identifier are added to the header of the data frame.

[0040] When transmitting different types of data through independently shielded lines, signal amplification components are installed at both ends of the line to amplify the data signal to the standard transmission amplitude, ensuring signal integrity after long-distance transmission.

[0041] In this embodiment, it should be noted that the voltage, internal resistance, and temperature data of the two 15000mAh independent lithium-ion cells are respectively marked as "VOL", "RES", and "TMP". A millisecond-level timestamp in "YYYYMMDDHHMMSSfff" format, generated by the built-in clock module of the IPM-900 intelligent power management unit, and the serial numbers "BAT01" (first cell) and "BAT02" (second cell) are added to the header of each data frame.

[0042] For example, the voltage data frame of the first battery cell at a certain moment is "20240520143025123_BAT01_VOL_3.78V";

[0043] In this embodiment, three 0.5mm² multi-core shielded cables (1.2m in length, adapted to the internal layout of the equipment) are used to transmit three types of data respectively. AD823 signal amplification components are soldered to both ends of each shielded cable. The input end of the component is connected to the data acquisition end and the common ground, and the output end is connected to the corresponding receiving interface of the IPM-900 hub (voltage connected to V-RCV, internal resistance connected to R-RCV, temperature connected to T-RCV) and the hub's common ground. The component amplifies the voltage signal from 0.5V. The voltage is amplified to 2.0V±0.05V, the internal resistance signal is amplified from 0.3V to 1.5V±0.03V, and the temperature signal is amplified from 0.4V to 1.8V±0.04V. During amplification, the amplitude is stabilized by the built-in 10kΩ±1% feedback resistor. During transmission, the signal is monitored every 200ms by the IPM-900 hub signal detection module to ensure that the voltage signal fluctuation is ≤0.02V, the internal resistance signal fluctuation is ≤0.015V, and the temperature signal fluctuation is ≤0.02V, with no signal attenuation or distortion.

[0044] Optionally, after sending the control signal to the cell discharge circuit in step S2, the method further includes:

[0045] The intelligent power management unit collects data on the actual load at short intervals, and simultaneously collects the line temperature of the discharge circuit.

[0046] If the actual load deviates from the preset target load by more than the limit, and the line temperature does not exceed the safe operating range, then directly adjust the output amplitude of the control signal.

[0047] If the line temperature is close to the safe operating range, first reduce the adjustment range of the control signal, and simultaneously send fine-tuning instructions to the equipment load components.

[0048] In this embodiment, after the intelligent power management unit (model IPM-900) sends a control signal to the constructed dual 15000mAh battery cell discharge circuit, it collects the actual load of the discharge circuit through the built-in current detection module (detection accuracy ±10mA) at short intervals of 50ms. At the same time, it collects the line temperature through the PT100 platinum resistance temperature sensor deployed on the surface of the discharge circuit conductor (cross-sectional area 2.0mm² nickel-plated copper strip), with a temperature acquisition accuracy of ±0.3℃. The load and temperature data are synchronously stored in the hub's built-in storage unit (address 0x0060-0x009F).

[0049] For example, the preset target load for the discharge circuit is 5A ± 0.2A, the load deviation threshold is set to ± 0.5A, the safe operating range for line temperature is set to -10℃ to 60℃, and the threshold for approaching the safe range is set to 55℃. If the actual load is 5.6A (deviation 0.6A, exceeding ± 0.5A range) and the line temperature is 42℃ (not exceeding the -10℃ to 60℃ range), the IPM-900 hub directly adjusts the output amplitude of the control signal through the PWM signal output module, adjusting the initial output amplitude from 3.3V to 3.1V. After adjustment, the load is sampled at 50ms intervals until the actual load drops back to 5A ± 0.2A. The range is 0.2A. If the actual load is 5.7A (deviation 0.7A, out of range) and the line temperature is 56℃ (close to the 55℃ threshold), the IPM-900 hub will first reduce the control signal adjustment amplitude from the usual 0.2V / time to 0.1V / time, and adjust the output amplitude from 3.3V to 3.2V. At the same time, it will send a fine-tuning command to the load component (such as the G99 main chip) of the industrial-grade ruggedized tablet PC through the I2C communication interface. The command is to reduce the component's operating power from 15W to 13W. After the adjustment and command are sent, the load and temperature will still be collected at 50ms intervals until the actual load and line temperature meet the requirements.

[0050] Optionally, the dynamic load balancing allocation for the two cells in step S2 is specifically as follows:

[0051] Based on the intelligent power management unit, cell voltage matching curve and temperature adaptability curve are established respectively. The voltage matching curve is based on the rated voltage to mark the real-time voltage fluctuation range, and the temperature adaptability curve is based on the normal operating temperature to mark the real-time temperature deviation range.

[0052] When the voltage fluctuation range of the first cell is within ±2% of the rated voltage and the temperature deviation range is within 5℃ below the normal operating temperature, while the second cell exceeds this range, a stepped load increase signal is sent to the discharge circuit of the first cell, gradually increasing to the target load ratio in 3 steps, and a synchronous stepped load decrease signal is sent to the discharge circuit of the second cell.

[0053] In this embodiment, the IPM-900 intelligent power management unit establishes cell voltage matching curves and temperature adaptability curves based on real-time data from two independent 15000mAh lithium-ion cells. The voltage matching curve uses the cell's rated voltage of 3.7V as a benchmark and marks the real-time voltage fluctuation range (accuracy ±0.01V). The temperature adaptability curve uses the cell's normal operating temperature of 25℃ as a benchmark and marks the real-time temperature deviation range (accuracy ±0.1℃).

[0054] In this embodiment, for example, the acceptable voltage fluctuation range is set to ±2% of the rated voltage of 3.7V (i.e., 3.626V-3.774V), and the acceptable temperature deviation range is set to ±5℃ of the normal operating temperature of 25℃ (i.e., 20℃-30℃). When the real-time voltage of the first cell (identified as BAT01) is 3.72V (fluctuation range of 0.02V, within 3.626V-3.774V) and the real-time temperature is 28℃ (deviation range of 3℃, below 20℃-30℃), and the real-time voltage of the second cell (identified as BAT02) is 3.58V (fluctuation range of 0.12V, exceeding the acceptable range) and the real-time temperature is 32℃ (deviation range of 7℃, exceeding the acceptable range), the IPM-900 hub... A stepped load increase signal is sent to the discharge circuit of the first cell via the discharge control interface (CTRL-D1). The initial load ratio is 40%, which is increased to 55% for the first time, then to 70% after a 100ms interval, and then to 85% (target load ratio) after another 100ms interval. Simultaneously, a stepped load decrease signal is sent to the discharge circuit of the second cell via the discharge control interface (CTRL-D2). The initial load ratio is 60%, which is decreased to 45% for the first time, then to 30% after a 100ms interval, and then to 15% after another 100ms interval. After each signal is sent, the actual load of the two discharge circuits is collected by the built-in current detection module (accuracy ±10mA) to ensure that the load ratio adjustment deviation is ≤2%.

[0055] Optionally, the alternating main discharge switching between the two cells in step S2 is specifically as follows:

[0056] The intelligent power management unit simultaneously collects the rate of change of internal resistance of the two cells while monitoring the temperature difference and main discharge duration.

[0057] When the temperature difference reaches the target or the main discharge time reaches the target, compare the rate of change of internal resistance. If the rate of change of internal resistance of the cell currently undergoing main discharge is higher than that of another cell, then accelerate the load deceleration rate.

[0058] If the resistance is lower, the rate is slowed down, and the load of the two cells is adjusted by dynamically controlling the internal resistance value to complete the shock-free switching.

[0059] In this embodiment, the IPM-900 intelligent power management unit is selected and connected to the discharge circuit of two independent 15000mAh lithium-ion cells (denoted as cell A and cell B, with cell A being the main discharge cell). The IPM-900 hub collects real-time temperature data through the NTC thermistor (temperature range -20℃ to 85℃, accuracy ±0.5℃) built into the TC-F03 elastic detection contacts deployed on the sidewalls of the two cells, calculates the temperature difference (temperature of cell A - temperature of cell B), and simultaneously records the temperature of cell A through the hub's built-in timing module. The main discharge duration is timed with an accuracy of ±100ms. Simultaneously, the internal resistance of the two cells is collected via a built-in AC impedance detection module (detection frequency 1kHz, AC excitation current 100mA, accuracy ±5mΩ). Internal resistance data is collected every 80ms, and the rate of change of internal resistance is calculated using the formula "(current internal resistance - previous internal resistance) / previous internal resistance × 100%", with the result retained to three decimal places. The temperature difference threshold is set at 5℃, the main discharge duration threshold is set at 1200s, and the compatible internal resistance range is 80mΩ-120mΩ.

[0060] When the temperature difference between cell A and cell B reaches 5℃ (temperature difference meets standard), or the main discharge time of cell A reaches 1200s (main discharge time meets standard), the IPM-900 hub retrieves the real-time internal resistance change rate of the two cells. If the internal resistance change rate of cell A is 0.852% and that of cell B is 0.421% (cell A is higher than cell B), then the load deceleration rate of cell A is increased from the normal 0.5% / 100ms to 1.2% / 100ms, and the load deceleration rate of cell B is simultaneously increased from the normal 0.5% / 100ms to 1.2% / 100ms. If the internal resistance change rate of cell A is 0.315% and that of cell B is 0.683% (cell A is lower than cell B), then the load deceleration rate of cell A is increased from the normal 0.5% / 100ms to 1.2% / 100ms. The load deceleration rate of cell A is reduced from 0.5% / 100ms to 0.2% / 100ms, and the load increase rate of cell B is simultaneously reduced to 0.2% / 100ms. During the adjustment process, the IPM-900 hub monitors the internal resistance of the two cells in real time and dynamically controls the load adjustment amplitude through the PWM signal output module, so that the internal resistance of the two cells is always maintained within the matching internal resistance range of 80mΩ-120mΩ. After each adjustment, the discharge current of the two cells is collected at 50ms intervals (detection accuracy ±10mA) to ensure that the current fluctuation amplitude is ≤0.1A, until the load of cell A drops to 20% and the load of cell B rises to 80%, completing the shockless switching of the main discharge cells from A to B.

[0061] Preferably, step S3: continuously monitor the operating data of the two cells. When the operating data of either cell exceeds the preset range, send a command to the circuit switch corresponding to that cell to perform single-circuit isolation and disconnection, while maintaining a stable connection between the other normal cell and the main circuit.

[0062] Optionally, the continuous monitoring of the operating data of the two cells in step S3 includes:

[0063] When the intelligent power management unit adjusts the acquisition cycle according to the device load level, it simultaneously establishes a load-cycle correspondence table, with high load corresponding to a short acquisition cycle and low load corresponding to a long acquisition cycle.

[0064] When the data acquisition deviation exceeds the range, the data transmission of the current cell is first paused, and the data is re-acquired twice and compared with the original data. If the deviation of the two newly acquired data is less than the original deviation, the original data is replaced. If it still exceeds the range, the cell monitoring self-test program is triggered.

[0065] In one embodiment, the IPM-900 intelligent power management unit connects to the discharge circuit of two independent 15000mAh lithium-ion cells. First, it obtains the real-time load level of the device through the I2C communication interface with the industrial-grade ruggedized tablet computer load component (such as the G99 main chip). The load level is divided into high load (10W-15W), medium load (5W-10W), and low load (0W-5W). A load-cycle correspondence table is established simultaneously, where high load corresponds to a 50ms acquisition cycle, medium load corresponds to a 100ms acquisition cycle, and low load corresponds to a 200ms acquisition cycle. The correspondence table is stored in the hub's built-in storage unit (address 0x00A0-0x00C0).

[0066] It should be noted that the hub collects voltage (16-bit AD sampling accuracy, range 3.2V-4.2V) and temperature (NTC thermistor, range -20℃-85℃, accuracy ±0.5℃) data of the two cells through the TC-F03 elastic detection contact. The voltage data deviation threshold is set to ±0.05V and the temperature data deviation threshold is set to ±2℃.

[0067] In another embodiment, when the voltage of the first battery cell (identified as BAT01) is 3.78V at a certain moment, and after one acquisition cycle (the current load is 12W, corresponding to a 50ms cycle), the acquired voltage is 3.65V, with a deviation of 0.13V (out of ±0.05V range), the hub immediately pauses the data transmission of the first battery cell, and after an interval of 20ms, re-acquires the voltage data twice, which are 3.76V and 3.77V respectively. The deviation between the two newly acquired data is calculated to be 0.01V (less than the original deviation of 0.13V), so the original 3.65V data is replaced with 3.77V (the average of the two data).

[0068] In another embodiment, if the two re-collected voltage data are 3.64V and 3.63V, with a deviation of 0.01V but still below the lower limit of the qualified voltage range of 3.626V (out of range), the hub triggers the built-in cell monitoring self-test program. After the self-test program is started, the fast charging circuit of the first cell is disconnected first, and then the internal resistance of the cell is re-detected through the AC impedance detection module (1kHz frequency, 100mA excitation current). At the same time, the pressure of the TC-F03 elastic detection contact (ensuring 0.8N-1.2N) and the connection status of the line are checked. The self-test data is stored in real time in the hub fault log area (address 0x00D0-0x00FF).

[0069] Optionally, step S3, which involves performing single-channel isolation and disconnection on the abnormal cell, includes:

[0070] When the intelligent power management unit collects abnormal cell data for the second time, it adopts cross-collection. The first time, it collects data through the cell's built-in detection line, and the second time, it collects data through the device's mainboard backup detection line.

[0071] If both data acquisition channels are out of range, a trigger command is sent to the circuit switch. The switch first disconnects the cell from the fast charging circuit, and then disconnects the cell from the main discharge circuit after the circuit voltage stabilizes. At the same time, the cell status data at the moment of disconnection is recorded.

[0072] In this embodiment, when the IPM-900 intelligent power management unit detects abnormal data (e.g., voltage 3.52V, exceeding the acceptable range of 3.626V-3.774V) in the second of the two split 15000mAh independent lithium-ion cells (identified as BAT02), it initiates secondary cross-data acquisition. The first acquisition uses the cell's built-in TC-F03 elastic detection contact circuit to acquire voltage (accuracy ±0.01V) and temperature (accuracy ±0.5℃). The second acquisition uses the industrial-grade ruggedized tablet motherboard's backup detection circuit (0.3mm² multi-core shielded cable, connected to the motherboard's backup sensor interface J12) to acquire the same type of data. If the built-in circuit measures 3.51V and the temperature is 22℃, and the backup circuit measures 3.50V and the temperature is 21℃, both voltages are <3. If the voltage is 626V (out of range), the hub sends a trigger command to the SSM3K154 circuit switch via the CTRL-SW interface. The switch first disconnects the battery cell from the PD-33W fast charging circuit (delay 10ms). After the hub's voltage detection module (16-bit AD sampling) detects that the battery cell output voltage is stable at 3.5V±0.02V (fluctuation ≤0.01V for 3 consecutive samplings), it then disconnects the battery cell from the main discharge circuit (delay 50ms). At the same time, the hub records the disconnection time data, including a millisecond-level timestamp (YYYYMMDDHHMMSSfff), instantaneous voltage 3.50V, instantaneous temperature 21℃, and instantaneous internal resistance 98.5mΩ (measured by the AC impedance module). The data is stored in the hub's 0x0100-0x013F fault storage area and retained for 90 days.

[0073] Optionally, maintaining normal cell connectivity with the main circuit in step S3 includes:

[0074] When the intelligent power management unit adjusts the normal cell protection parameters, it adopts a segmented increase. First, the overcurrent protection upper limit is increased to 1.1 times the normal value and maintained for 30 seconds. After the discharge current is collected and there are no abnormalities, it is then increased to the target multiple.

[0075] At the same time, a temporary buffer resistor is added at the connection point between the battery cell and the main circuit to avoid current surges caused by parameter adjustments.

[0076] In this embodiment, after the IPM-900 intelligent power management unit confirms that the first cell (identified as BAT01) of the two separate 15000mAh independent lithium-ion cells is a normal cell and the second cell (identified as BAT02) has been disconnected, it begins to adjust the protection parameters of the first cell. The conventional overcurrent protection upper limit of this cell is set to 8A, and the target multiple is set to 1.3 times (i.e., the target overcurrent protection upper limit is 10.4A). The adjustment adopts a segmented increase method. First, the overcurrent protection upper limit is increased from 8A to 8.8A (1.1 times the conventional value) through the hub protection parameter configuration module, and this parameter is maintained for 30 seconds. During the maintenance period, the current detection module built into the hub (accuracy ±10mA) collects the data of the first cell every 5 seconds. If the collected discharge currents of the battery cell are 6.2A, 6.1A, 6.3A, 6.2A, 6.1A, and 6.3A respectively (none exceeding 8.8A and fluctuation ≤0.2A, indicating no abnormality), then the overcurrent protection upper limit will be increased from 8.8A to 10.4A. At the same time, a temporary buffer resistor of model RX-050 is connected in series at the connection point (nickel-plated copper strip connection) between the first battery cell and the main discharge circuit. The resistance value is set to 0.1Ω and the rated power is 5W. Through voltage division buffering, current surges are avoided during parameter adjustment. After the buffer resistor is connected in series, the voltage change at the connection point is monitored by the hub voltage detection module (16-bit AD sampling accuracy) to ensure that the voltage fluctuation before and after parameter adjustment is ≤0.2V.

[0077] Preferably, in step S4: when the industrial mobile device is connected to an external power source and the power supply meets the preset requirements, the two fast charging circuits are controlled to start synchronously to perform parallel collaborative fast charging on the dual-cell battery.

[0078] Most importantly, step S4, which controls the simultaneous activation of the two fast charging circuits to perform parallel collaborative fast charging of the dual-cell batteries, specifically involves:

[0079] First, the real-time power supply and voltage stability of the external power supply are detected by the intelligent power management unit. When the power supply meets the preset power requirements for 10-15 seconds and the voltage fluctuation is ≤±2%, a start signal is sent to the two fast charging circuits.

[0080] During the initial startup, the dual-cell battery is charged at 50% of the rated fast charging power, while the initial temperature and voltage of the dual-cell battery are collected.

[0081] If the temperature of both cells is below 35℃ and the voltage difference is ≤0.03V, the fast charging power will be gradually increased to the rated value. During this period, the cell temperature will be collected every 2-3 seconds. If the temperature of either cell exceeds 40℃, the fast charging power of that circuit will be reduced by 10%-15%.

[0082] The intelligent power management unit compares the charging progress difference between the two cells in real time. When the difference exceeds 8% of the total capacity, it sends a power compensation signal to the fast charging circuit corresponding to the cell with slower charging progress, thereby increasing the fast charging power of that circuit by 5%-8%.

[0083] At the same time, reduce the power of the fast charging circuit corresponding to the cell with faster charging progress by 3%-5% until the difference in charging progress between the two cells is reduced to within 5%, thereby achieving synchronization of the charging progress of the two cells.

[0084] In one embodiment, the IPM-900 intelligent power management unit first collects the real-time power supply (detection accuracy ±5W) and voltage (detection accuracy ±0.1V) of the external power supply through a power detection interface connected to the 19V / 3.5A DC power supply after conversion by an AC-1206 AC-DC converter from an external 220V / 50Hz AC power supply. The preset total power supply required by the two PD-33W fast charging circuits is 66W. When the power supply is monitored to be stable at 66W-70W for 12 seconds (meeting the preset power requirement) and the voltage fluctuation is stable at 19V±0.38V (≤±2%), a start signal is sent to the two PD-33W fast charging circuits through the fast charging control interface (CHG-CTRL1, CHG-CTRL2). Initially, both fast charging circuits charge the two 15000mAh independent lithium-ion cells separated in step S1 at 16.5W (50% of the rated fast charging power). Simultaneously, the IPM-900... The M-900 hub uses a TC-F03 elastic sensing contact with a built-in NTC thermistor (accuracy ±0.5℃) to collect the initial temperature of the two battery cells, and a 16-bit AD sampling module (accuracy ±0.01V) to collect the initial voltage. If the initial temperature of the first battery cell (marked BAT01) is 32℃ and the initial voltage is 3.65V, and the initial temperature of the second battery cell (marked BAT02) is 31℃ and the initial voltage is 3.63V, then both battery cell temperatures are below 35℃ and the voltage difference is... If the value is 0.02V (≤0.03V), the two fast charging powers will be simultaneously increased by 16.5W every 3 seconds, increasing to the rated value of 33W in two steps. During the power increase, the temperature of the two cells will be collected every 2 seconds. If the temperature of the first cell rises to 41℃ (above 40℃), the corresponding PD-33W fast charging power will be reduced from 33W to 28.05W (reduced by 15%) through the CHG-CTRL1 interface until the temperature of the cell drops back below 40℃.

[0085] In another embodiment, when the IPM-900 intelligent power management unit controls two PD-33W fast charging circuits to perform parallel collaborative fast charging on the two 15000mAh independent lithium-ion cells (identified as BAT01 and BAT02) split in step S1, it collects the charging progress of the two cells in real time (measured as a percentage of the remaining capacity relative to the total 15000mAh capacity) through a built-in power metering module (accuracy ±1%), and calculates the progress difference. When it detects that the charging progress of BAT01 is 65% and the charging progress of BAT02 is 55%, with a difference of 10% (exceeding 8% of the total capacity), the IPM-900 hub sends a signal to BAT02 via the fast charging control interface CHG-CTRL2. The corresponding PD-33W fast charging circuit sends a power compensation signal to increase its fast charging power from 33W to 35.64W (an 8% increase). At the same time, it sends a power adjustment signal to the corresponding PD-33W fast charging circuit of BAT01 through the CHG-CTRL1 interface to reduce its fast charging power from 33W to 31.65W (a 3% decrease). After the power adjustment, the charging progress of the two cells is collected every 5 seconds through the power metering module, and the progress difference is continuously monitored until the charging progress of BAT01 reaches 72% and the charging progress of BAT02 reaches 68%, and the difference is reduced to 4% (≤5%). At this point, the power compensation and adjustment are stopped, and the two fast charging circuits continue to charge at the rated power of 33W.

[0086] Preferably, in step S5: when the industrial mobile device is in a discharging state and the load power is lower than the maximum discharge power of a single cell, control the single cell to perform main power output while the other cell remains in low-power standby mode.

[0087] Of particular importance is that step S5, which involves controlling one battery cell to perform main power output while the other battery cell remains in low-power standby mode, includes:

[0088] First, the real-time load current of industrial mobile equipment is collected by a current sensor, and the feasibility of single-cell main power supply is determined by combining the rated discharge current of the battery cell.

[0089] When selecting the main power supply cell, prioritize cells with fewer historical cycle counts and lower capacity decay rate in the last charge-discharge cycle;

[0090] At the same time, the circuit connection terminal of the standby battery cell is switched to a low-power sleep circuit, cutting off the connection between the standby battery cell and unnecessary discharge circuits, and only retaining the communication link with the intelligent power management unit, so that the static power consumption of the standby battery cell is controlled within 5mA.

[0091] In this embodiment, when the industrial-grade ruggedized tablet is in a discharging state, the IPM-900 intelligent power management unit first collects the real-time load current of the device through an ACS712 current sensor (detection range 0-20A, accuracy ±0.1A) connected in series in the main discharge circuit. Combined with the rated discharge current of 5A of the two 15000mAh independent lithium-ion cells (identified as BAT01 and BAT02) split in step S1, the feasibility of single-cell main power supply is determined. When the collected real-time load current is 3.2A (below 5A), it is determined that a single cell can provide main power. Subsequently, the IPM-900 hub retrieves the historical data of the two cells, where BAT01 has a historical cycle count of 80 and a capacity decay rate of 2.1% from the last charge-discharge cycle, and BAT02 has a historical... With a cycle count of 120 and a capacity decay rate of 3.5% from the last charge-discharge cycle, BAT01 is selected as the primary power supply cell. Simultaneously, a switching command is sent to the SSM3K154 circuit switch corresponding to BAT02 via the control interface CTRL-SL to switch its circuit connection from the main discharge circuit to the low-power sleep circuit. This disconnects BAT02 from unnecessary discharge circuits (such as expansion interfaces and backup sensors) in the peripheral equipment, leaving only the I2C communication link with the IPM-900 hub (communication current ≤2mA). The hub power consumption monitoring module (accuracy ±0.1mA) monitors the power consumption in real time to ensure that the static power consumption of BAT02 is controlled within 5mA. BAT01 then continuously outputs 3.2A current through the main discharge circuit to meet the equipment load requirements.

[0092] Optionally, this invention also proposes a four-in-one system-level implementation scheme integrating a dual-cell architecture, three heat dissipation channels, structural support, and intelligent scheduling:

[0093] 1. Dual-battery unit parallel management and intelligent scheduling system:

[0094] Implementation principle: The total capacity of 30000mAh is divided into two independent 15000mAh cells, which are managed in parallel through a set of intelligent power management unit chips.

[0095] Parallel fast charging: Supports two independent charging circuits, which can simultaneously charge two battery cells at 33W, theoretically reducing the total charging time by nearly 50%.

[0096] Intelligent load balancing: During discharge, the intelligent hub dynamically allocates the output load based on the real-time status (temperature, voltage, internal resistance) of the two cells. It prioritizes the use of the cell in better condition or allows the two cells to work alternately, thereby balancing degradation and extending the overall battery pack life.

[0097] Fault isolation: When one of the battery cells malfunctions (such as overheating or short circuit), the smart hub can immediately isolate it from the circuit, and only the other healthy battery cell continues to supply power, greatly improving the system's safety redundancy.

[0098] 2. Multimodal active thermal management system:

[0099] Implementation principle: To cope with the enormous heat generated by dual-cell fast charging and high-load operation, a triple heat dissipation channel was designed:

[0100] Thermal conductive gel + vapor chamber (VC): High-performance thermal conductive materials are covered on the surfaces of high-heat-generating components such as battery cells and main chip (G99) to quickly conduct heat to the metal frame.

[0101] Intelligent fan active cooling: A miniature centrifugal fan is integrated inside the device, intelligently starting and stopping based on temperature sensor data. This is a dedicated solution designed for "thicker" models, utilizing the increased thickness to achieve active air cooling, something that ordinary thin and light devices cannot achieve.

[0102] Structural cooling ducts: Airflow ventilation ducts are designed in the internal layout and structural components of the equipment. Working in conjunction with the fan, hot air is exhausted from the hidden opening at the top of the equipment, forming an effective circulation.

[0103] 3. "Battery compartment" type structural reinforcement and modular design:

[0104] Implementation principle: Abandoning the method of simply pasting the battery to the back cover, it innovatively adopts an independent, integrated metal battery compartment.

[0105] High-strength support: The battery compartment is CNC machined from aluminum alloy, providing robust support and protection for the two heavy-duty battery cells, greatly enhancing the overall structural strength of the equipment and enabling it to withstand greater impacts and drops.

[0106] Heat dissipation: The metal battery compartment itself is also a huge heat sink, which helps to evenly dissipate the heat generated by the battery to the entire back of the device.

[0107] 4. Scenario-based power consumption strategies for ultra-long battery life:

[0108] Implementation principle: Provide multiple power consumption modes (such as "extreme battery life mode" and "performance mode") at the software layer.

[0109] In "Extreme Battery Life Mode", the system will automatically shut down non-core functions (such as high refresh rate, some sensors, and background synchronization), significantly reduce screen brightness, and limit CPU performance to a baseline level, thereby pushing the device's battery life to the extreme and meeting the needs of offline work for several days or even more than a week.

[0110] Therefore, the embodiments should be considered as exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of the equivalents of the application are intended to be included within the invention.

[0111] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features of the invention herein.

Claims

1. A dual battery unit management method for an industrial mobile device, characterized by, Includes the following steps: Step S1: The battery pack of the industrial mobile device is split into two independent cells and connected to the intelligent power management unit in parallel. Each cell is configured with a fast charging circuit, so that each fast charging circuit forms a dual independent closed-loop control path with the external power supply, the corresponding cell and the intelligent power management unit. Step S2: Collect real-time operating data of the two cells and transmit it to the intelligent power management unit. At the same time, send control signals to the cell discharge circuit to perform dynamic load balancing or alternating main discharge switching on the two cells. Specifically, step S2 involves alternating main discharge switching between the two battery cells as follows: The intelligent power management unit simultaneously collects the rate of change of internal resistance of the two cells while monitoring the temperature difference and main discharge duration. When the temperature difference reaches the target or the main discharge time reaches the target, compare the rate of change of internal resistance. If the rate of change of internal resistance of the cell currently undergoing main discharge is higher than that of another cell, then accelerate the load deceleration rate. If the speed is lower, the rate is slowed down, and the load of the two cells is adjusted by dynamically controlling the internal resistance value to complete the shock-free switching. Step S3: Continuously monitor the operating data of the two cells. When the operating data of either cell exceeds the preset range, send a command to the circuit switch corresponding to that cell to perform single-circuit isolation and disconnection, while maintaining a stable connection between the other normal cell and the main circuit. Step S4: When the industrial mobile device is connected to an external power source and the power supply meets the preset requirements, control the two fast charging circuits to start synchronously to perform parallel collaborative fast charging of the dual-cell batteries; Step S5: When the industrial mobile device is in a discharging state and the load power is lower than the maximum discharge power of a single cell, control the single cell to perform main power output while the other cell remains in low-power standby mode.

2. The dual battery unit management method for an industrial mobile device according to claim 1, characterized by, The specific steps for collecting real-time operating data from the two battery cells in step S2 are as follows: Elastic detection contacts are deployed on the tabs and sidewalls of the positive and negative terminals of the two cells respectively. The elastic detection contacts have built-in miniature pressure sensors. Before data collection, the contact pressure is adjusted to a suitable contact state through sensor feedback. After the pre-power-on stabilization signal is established, multiple sets of data are continuously collected for each parameter in the order of voltage, internal resistance, and temperature. The median value of each set of data is taken, extreme values ​​are removed, and the average value is calculated.

3. The dual battery unit management method for industrial mobile devices according to claim 1, characterized by, The specific steps in step S2 involving transmission to the intelligent power management unit are as follows: After acquisition, the voltage, internal resistance, and temperature data are marked in a time-division manner, and the acquisition timestamp and cell number identifier are added to the header of the data frame. When transmitting different types of data through independently shielded lines, signal amplification components are installed at both ends of the line to amplify the data signal to the standard transmission amplitude, ensuring signal integrity after long-distance transmission.

4. The dual battery unit management method for industrial mobile devices according to Claim 1, characterized by, After sending the control signal to the cell discharge circuit in step S2, the following steps are also included: The intelligent power management unit collects data on the actual load at short intervals, and simultaneously collects the line temperature of the discharge circuit. If the actual load deviates from the preset target load by more than the limit, and the line temperature does not exceed the safe operating range, then directly adjust the output amplitude of the control signal. If the line temperature is close to the safe operating range, first reduce the adjustment range of the control signal, and simultaneously send fine-tuning instructions to the equipment load components.

5. The dual-battery cell management method for industrial mobile devices according to claim 1, characterized in that, The specific steps for performing dynamic load balancing on the two battery cells in step S2 are as follows: Based on the intelligent power management unit, cell voltage matching curve and temperature adaptability curve are established respectively. The voltage matching curve is based on the rated voltage to mark the real-time voltage fluctuation range, and the temperature adaptability curve is based on the normal operating temperature to mark the real-time temperature deviation range. When the voltage fluctuation range of the first cell is within ±2% of the rated voltage and the temperature deviation range is within 5℃ below the normal operating temperature, while the second cell exceeds this range, a stepped load increase signal is sent to the discharge circuit of the first cell, gradually increasing to the target load ratio in 3 steps, and a synchronous stepped load decrease signal is sent to the discharge circuit of the second cell.

6. The dual-battery cell management method for industrial mobile devices according to claim 1, characterized in that, Step S3 involves continuously monitoring the operating data of the two battery cells, including: When the intelligent power management unit adjusts the acquisition cycle according to the device load level, it simultaneously establishes a load-cycle correspondence table, with high load corresponding to a short acquisition cycle and low load corresponding to a long acquisition cycle. When the data acquisition deviation exceeds the range, the data transmission of the current cell is first paused, and the data is re-acquired twice and compared with the original data. If the deviation of the two newly acquired data is less than the original deviation, the original data is replaced. If it still exceeds the range, the cell monitoring self-test program is triggered.

7. The dual-battery cell management method for industrial mobile devices according to claim 1, characterized in that, Step S3, which involves performing single-channel isolation and disconnection on the abnormal battery cell, includes: When the intelligent power management unit collects abnormal cell data for the second time, it adopts cross-collection. The first time, it collects data through the cell's built-in detection line, and the second time, it collects data through the device's mainboard backup detection line. If both data acquisition channels are out of range, a trigger command is sent to the circuit switch. The switch first disconnects the cell from the fast charging circuit, and then disconnects the cell from the main discharge circuit after the circuit voltage stabilizes. At the same time, the cell status data at the moment of disconnection is recorded.

8. The dual-battery cell management method for industrial mobile devices according to claim 1, characterized in that, Step S3, maintaining normal cell connection with main circuit, includes: When the intelligent power management unit adjusts the normal cell protection parameters, it adopts a segmented increase. First, the overcurrent protection upper limit is increased to 1.1 times the normal value and maintained for 30 seconds. After the discharge current is collected and there are no abnormalities, it is then increased to the target multiple. At the same time, a temporary buffer resistor is added at the connection point between the battery cell and the main circuit to avoid current surges caused by parameter adjustments.

9. A dual-battery cell management system for industrial mobile equipment, characterized in that, For performing the dual-battery cell management method for industrial mobile devices as described in claim 1, the dual-battery cell management system for industrial mobile devices includes: The dual-cell parallel architecture module is used to split the battery pack of industrial mobile equipment into two independent cells, which are connected to the intelligent power management unit in parallel. Each cell is configured with a fast charging circuit, so that each fast charging circuit forms a dual independent closed-loop control path with the external power supply, the corresponding cell and the intelligent power management unit. The dual-cell monitoring and control module is used to collect real-time operating data of the two cells and transmit it to the intelligent power management unit. At the same time, it sends control signals to the cell discharge circuit to perform dynamic load balancing or alternating main discharge switching on the two cells. The dual-cell single-path isolation module is used to continuously monitor the operating data of two cells. When the operating data of either cell exceeds the preset range, a command is sent to the circuit switch corresponding to that cell to perform single-path isolation and disconnection, while maintaining a stable connection between the other normal cell and the main circuit. The dual-cell parallel fast charging control module is used to control two fast charging circuits to start synchronously to perform parallel collaborative fast charging of the dual cells when the industrial mobile equipment is connected to an external power source and the power supply meets the preset requirements. The dual-cell power supply mode switching module is used to control one cell to perform main power output and the other cell to remain in low-power standby mode when the industrial mobile equipment is in a discharging state and the load power is lower than the maximum discharge power of a single cell.

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