Mobile energy storage intelligent balancing management and control system based on supercapacitor modules

Abstract

This invention belongs to the field of energy storage technology, specifically a mobile intelligent energy storage balancing and management system based on supercapacitor modules. It includes an energy storage module composed of multiple supercapacitor cells connected in series; a high-precision synchronous sampling unit for real-time acquisition of terminal voltage, temperature, and leakage current parameters of each supercapacitor cell, supporting millisecond-level synchronous triggering; a lightweight active balancing unit that achieves directional energy transfer between adjacent or spanning cells through a multi-channel controllable MOSFET switching network; and, based on millisecond-level synchronous data, integrating load condition identification and cell aging prediction models, dynamically generating and executing a feedforward-feedback composite balancing strategy. This allows the system to trigger preventative balancing operations before drastic parameter changes occur due to moving bumps, pulse discharges, or other conditions, suppressing inconsistencies at their inception. This significantly improves the timeliness, accuracy, and energy utilization efficiency of balancing, extending the overall lifespan of the module.

Description

Technical Field

[0001] This invention belongs to the field of energy storage technology, specifically a mobile energy storage intelligent balance management and control system based on supercapacitor modules. Background Technology

[0002] A supercapacitor module is an energy storage unit composed of multiple supercapacitor cells connected in series and parallel. Supercapacitor cells themselves are characterized by high power density, long cycle life, and fast charge / discharge speeds, but their individual voltages are relatively low. To meet the demands of mobile devices for higher operating voltages and larger capacities, dozens or even hundreds of cells are typically connected in series. However, due to differences in manufacturing processes, material properties, and operating environments, inconsistencies exist in the parameters of each cell. These inconsistencies accumulate during cyclic use, directly affecting the overall performance and lifespan of the module.

[0003] In the field of mobile energy storage, such as electric vehicles, hybrid engineering machinery, portable emergency power supplies, and special equipment, supercapacitor modules play a crucial role due to their superior power response and environmental adaptability. These applications require energy storage systems to not only operate stably under harsh conditions such as wide temperature ranges and strong vibrations, but also to cope with dynamic operating conditions such as frequent pulse charging and discharging and regenerative braking. The reliability, energy availability, and maintenance costs of the modules directly depend on the level of consistent management of the status of each individual unit within them.

[0004] Current technologies still have significant shortcomings in addressing highly dynamic mobile applications, specifically: First, existing equalization systems suffer from bottlenecks in the synchronization of data acquisition and the timeliness of strategy response. Most solutions employ sequential or group sampling, making it difficult to achieve strict synchronous capture of key parameters such as voltage and temperature of all individual units. This asynchrony can lead to misjudgments when the load changes drastically. Simultaneously, traditional comparison triggering methods based on fixed threshold hysteresis are slow to respond and cannot predict changes in operating conditions before they occur, resulting in equalization lag and exacerbating inconsistencies. Second, common equalization circuit topologies struggle to balance efficiency, size, and self-sufficiency. While resistive dissipative equalization is simple in structure, energy is wasted as heat, making it unsuitable for energy-intensive mobile scenarios. Inductive active equalization is more efficient, but the magnetic components are large and costly, and have weak vibration resistance, failing to meet the requirements for compact and highly reliable packaging. Furthermore, most active equalization solutions require additional auxiliary power supplies, increasing system complexity and potential failure points. Third, equalization control strategies are singular and rigid, lacking intelligent adaptation to application scenarios and individual unit states. Existing strategies are mostly passive feedback control based on the current voltage deviation, which do not fully consider the impact of the variable operating conditions faced by mobile devices, such as bumps, vibrations, pulse impacts, and stationary drift, on parameter measurement and balancing effectiveness. They also do not incorporate the long-term trend of cell aging and degradation. This leads to the balancing process being frequently started when unnecessary, wasting energy, or failing to act when critical needs are met, resulting in low overall balancing efficiency and the inability to proactively maintain the health status of the modules. Therefore, to address the above problems, a mobile energy storage intelligent balancing management and control system based on supercapacitor modules is proposed. Summary of the Invention

[0005] To overcome the shortcomings of existing technologies and solve at least one of the technical problems mentioned in the background art, this invention proposes a mobile energy storage intelligent balance management and control system based on supercapacitor modules.

[0006] The technical solution adopted by the present invention to solve its technical problem is: the mobile energy storage intelligent balance management and control system based on supercapacitor modules of the present invention includes: an energy storage module composed of multiple supercapacitor cells connected in series. A high-precision synchronous sampling unit is used to collect the terminal voltage, temperature and leakage current parameters of each supercapacitor cell in real time, and supports millisecond-level synchronous triggering. The lightweight active balancing unit is integrated inside the energy storage module. It adopts a switched capacitor array topology and realizes directional energy transfer between adjacent or spanning cells through a multi-controllable MOSFET switching network. The edge intelligent management and control module has an embedded adaptive balancing scheduling algorithm. The algorithm is based on real-time data acquisition, load condition identification model and single-unit aging state prediction model to dynamically generate a feedforward to feedback composite balancing strategy. When the system is in any of the following conditions: moving bumps, pulse discharge or standby drift, it will trigger preventive balancing operation in advance. It also includes communication and security protection interfaces for interacting with the main control system of external mobile energy storage devices and for performing graded protection actions when detecting single-cell overvoltage, abnormal temperature rise, or equalization failure. The system is packaged as a compact module that can be embedded in vehicle, portable power supply or emergency equipment. It has vibration resistance and wide temperature range operation capability. The equalization process does not rely on external power supply, and energy is redistributed only between individual units within the module.

[0007] Preferably, the high-precision synchronous sampling unit ensures, through a hardware-level synchronous triggering mechanism, that the voltage, temperature and leakage current of all supercapacitor cells can still be sampled in time alignment when the mobile device experiences high-frequency vibration or sudden acceleration changes, thus avoiding misjudgment of the state due to asynchronous sampling.

[0008] Preferably, the lightweight active balancing unit adopts a coreless switched capacitor array topology, eliminating traditional inductor components, reducing size and weight, and supporting direct or indirect energy transfer between any two units, making it suitable for space-constrained vehicle or portable applications.

[0009] Preferably, the MOSFET switching network is configured as a bidirectional conduction structure, which allows energy to flow bidirectionally between adjacent cells and supports a span-jump mode to improve the balance, flexibility and response speed under non-uniform aging distribution.

[0010] Preferably, the edge intelligent management and control module independently completes working condition identification and aging status assessment without external cloud support, and dynamically adjusts the balanced start threshold and execution priority based on the fusion result of the two to achieve localized intelligent decision-making.

[0011] Preferably, the load condition identification model can distinguish four typical scenarios: moving bumps, pulse discharge, standby drift and steady-state operation, and preset differentiated equalization intervention logic for different scenarios, such as suppressing high-frequency equalization actions to avoid mechanical resonance under bumpy conditions.

[0012] Preferably, the single-unit aging state prediction model is based on multi-dimensional degradation feature fusion analysis, and uses abnormal leakage current growth, voltage recovery hysteresis and temperature rise sensitivity as aging indicators to identify potentially failed single units and guide the balanced priority allocation of resources.

[0013] Preferably, when the communication and security protection interface detects a leveling failure, it automatically switches to passive leveling mode as a backup protection and sends the fault type and suggested handling measures to the main control system to ensure the security of the system's degraded operation.

[0014] Preferably, the overall system packaging structure adopts an integrated anti-vibration bracket and thermal coupling design, so that the equalization unit, sampling circuit and supercapacitor unit form a rigid connection, effectively suppressing the deterioration of electrical contact caused by relative displacement during movement.

[0015] Preferably, the equalization process relies entirely on the energy stored inside the module, without introducing an external power source or additional energy storage components, and maintains continuous power supply during the equalization period to ensure uninterrupted power supply to the load in mobile application scenarios.

[0016] The beneficial effects of this invention are: This invention provides a mobile energy storage intelligent balancing and control system based on supercapacitor modules. By deploying a high-precision synchronous sampling unit and an edge intelligent control module with an embedded adaptive balancing scheduling algorithm, it achieves multi-dimensional real-time perception and proactive intelligent intervention of inconsistent module states. This system abandons the passive response mode of traditional sequential sampling and hysteresis comparison. Based on millisecond-level synchronous data, it integrates load condition identification and individual cell aging prediction models to dynamically generate and execute a feedforward-feedback composite balancing strategy. This allows the system to trigger preventative balancing operations before drastic parameter changes occur due to moving bumps, pulse discharges, or other conditions, suppressing inconsistencies at their inception. This significantly improves the timeliness, accuracy, and energy utilization efficiency of balancing, and extends the overall lifespan of the modules.

[0017] This invention provides a mobile energy storage intelligent balancing and control system based on supercapacitor modules. By employing a lightweight active balancing unit and its switched capacitor array topology integrated within the module, it achieves efficient, compact, and self-sustaining internal energy circulation and redistribution. This design utilizes a multi-channel controllable MOSFET switching network to flexibly realize directional energy transfer between adjacent or spaced cells. Its topology eliminates the need for bulky magnetic components, naturally offering advantages such as vibration resistance and ease of integration. More importantly, the balancing process relies entirely on the module's internal energy, eliminating the need for external auxiliary power. This not only simplifies the system structure and reduces energy consumption and thermal management burdens but also ensures reliable operation of the balancing function even in the event of external power failure, meeting the stringent requirements of mobile energy storage devices for high reliability, high power density, and compactness.

[0018] This invention provides a mobile energy storage intelligent equalization and control system based on supercapacitor modules. By encapsulating the entire system into a compact module with vibration resistance and wide temperature range operation capabilities, and integrating communication and safety protection interfaces, it achieves a highly integrated solution with plug-and-play functionality, adaptability to all operating conditions, and graded safety protection. This system can be seamlessly embedded as an independent functional module into the main control systems of various vehicle-mounted, portable, or emergency equipment. Its robust packaging and wide temperature range design ensure stable operation in harsh mobile environments; simultaneously, the intelligent graded protection mechanism can execute gradient actions from alarm to disconnection when overvoltage, abnormal temperature rise, or equalization failure is detected, providing dual protection for the mobile energy storage system from intelligent management to underlying security, greatly improving the availability and safety of the entire equipment. Attached Figure Description

[0019] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and are used to explain the invention, but do not constitute an undue limitation of the invention.

[0020] In the attached diagram: Figure 1 This is a schematic diagram of the system flow of the present invention; Figure 2 This is a block diagram of the high-precision synchronous sampling unit in this invention; Figure 3 This is a block diagram of the lightweight active balancing unit in this invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Specific implementation examples are given below.

[0023] Please see Figures 1-3 This invention provides a mobile energy storage intelligent balancing and control system based on a supercapacitor module, comprising: an energy storage module composed of multiple supercapacitor cells connected in series; a high-precision synchronous sampling unit; a lightweight active balancing unit; an edge intelligent control module; and a communication and safety protection interface. Each functional unit is tightly integrated with the power bus via a high-speed internal bus, and the whole is packaged into a compact anti-vibration module suitable for vehicle-mounted, portable power supplies or emergency equipment. It has a wide temperature range operation capability and does not rely on external power supply during the balancing process. Energy is only redistributed among the cells within the module, ensuring the continuity of power supply to external loads.

[0024] In some embodiments, such as Figures 1-3 As shown, the energy storage module structure and physical integration: This system adopts A storage module is composed of several commercial double-layer supercapacitor cells (typically N=24~96) with a rated voltage of 2.7V (such as Maxwell BMOD0063P125B04) connected in series. The total nominal voltage range is 64.8V~259.2V. All cells are mounted on an integrated anti-vibration bracket. The bracket is CNC machined from aerospace-grade aluminum alloy and anodized to improve insulation and heat dissipation efficiency. The bracket integrates a thermal coupling channel, which forms a rigid mechanical connection between the equalization unit, sampling circuit and capacitor cells, effectively suppressing solder joint fatigue or contact resistance degradation caused by relative displacement during vehicle bumps or equipment handling.

[0025] Each unit has a miniature thermistor (NTC, B value 3435K, resistance 10kΩ@25°C) attached to its bottom and tightly coupled to the metal base plate via thermal grease, ensuring a temperature acquisition response time of <50ms. High-precision synchronous sampling unit mechanism: To accurately obtain the status of each individual cell, the system is equipped with a high-precision synchronous sampling unit to collect the terminal voltage, casing temperature and leakage current of each supercapacitor cell in real time.

[0026] The key lies in the hardware-level synchronous triggering mechanism: all sampling channels are triggered uniformly by a synchronization pulse (SYNC) generated by the same FPGA, ensuring that all individual parameters are acquired within a millisecond time window. Even under conditions of high-frequency vibration or sudden acceleration changes, it can avoid misjudgment of voltage differences caused by asynchronous sampling, providing a reliable data foundation for subsequent equalization decisions.

[0027] Voltage measurement accuracy reaches ±1mV; temperature is calibrated using an NTC thermistor combined with the Steinhart-Hart equation, with an accuracy better than ±0.5°C; leakage current is indirectly measured through a high-side microampere detection circuit, with a resolution of 0.1μA.

[0028] In some embodiments, such as Figures 1-3 As shown, the lightweight active balancing unit: The equalization unit adopts a coreless switched capacitor array topology, eliminating traditional inductor components, significantly reducing size and weight, and making it suitable for space-constrained mobile platforms.

[0029] A flying capacitor is connected in parallel between each adjacent cell, and an H-bridge structure is formed by bidirectional MOSFET switches. This design supports two operating modes: Adjacent equilibrium: Energy is transferred between directly adjacent cells; Span equalization: Energy switching between non-adjacent cells is achieved through multi-stage capacitor relay.

[0030] Because there are no magnetic components, the system has low electromagnetic interference, and the equalization process relies entirely on the energy stored inside the module, without introducing an external power source or affecting the continuity of external power supply.

[0031] The amount of energy transferred during each equilibrium is closely related to the voltage difference between the two cells. Let the voltages of the two cells be... and Flying capacitor is Then the energy that can be transferred in a single operation is approximately: It is the span efficiency factor (which decreases as the jumper distance increases) used to reflect actual energy loss.

[0032] The equalization pulse width is dynamically calculated based on the voltage difference and the safe current limit to prevent overcurrent or overshoot.

[0033] Edge intelligent control and core algorithms: The edge intelligent management and control module operates independently based on an embedded processor, without cloud support, and can complete operating condition identification, aging assessment and balanced scheduling.

[0034] In some embodiments, such as Figures 1-3 As shown, the load condition identification model is as follows: The system has a built-in lightweight classification model that automatically identifies the current operating condition as one of the following four typical conditions based on real-time collected voltage fluctuations, temperature gradients, load current change rates, and acceleration information: For different operating conditions such as movement and turbulence, pulse discharge, standby drift, and steady-state operation, the system has preset differentiated equalization strategies. For example, under the "movement and turbulence" condition, high-frequency equalization actions are actively suppressed to avoid coupling between switching operations and mechanical resonance, thereby improving system robustness.

[0035] Monomer aging state prediction model To detect potential individual cells in advance, the system constructs an aging index. It integrates three key degradation features: Abnormal increase in leakage current; Voltage recovery is sluggish (reflecting an increase in internal resistance); Temperature rise increases the sensitivity to voltage changes.

[0036] The calculation formula is as follows: Among them, weight =0.4, =0.35, =0.25 was calibrated using historical aging data. When When the value is greater than 1.8, the monomer is considered to have an early aging risk.

[0037] In some embodiments, such as Figures 1-3 As shown, the adaptive load balancing scheduling algorithm The system adopts a combined "feedforward + feedback" equalization strategy: Feedforward: Based on the identified operating conditions, preventive equalization is initiated in advance (such as replenishing energy to low-voltage cells before pulse discharge). Feedback: Based on real-time voltage imbalance Trigger the balancing action.

[0038] The key innovation lies in dynamically adjusting the equilibrium start threshold: in =50, =0.3, This represents the current maximum aging index. This mechanism allows the system to intervene in balancing earlier as aging intensifies, preventing individual cells from becoming over-voltage.

[0039] Balanced execution priority (β=0.5), prioritize processing cells with large voltage deviations and severe aging to improve balancing efficiency and safety.

[0040] Communication and graded security protection: The system communicates with an external master controller via the CANFD bus to upload status data and fault information in real time.

[0041] The security protection adopts a graded mechanism: When an individual cell overvoltage (>2.85V) or abnormal temperature rise (>85°C) is detected, the relevant operation should be immediately restricted and an alarm should be issued. If the active balancing unit fails (such as a MOSFET short circuit), the system automatically switches to passive balancing mode (through a parallel bleeder resistor) as backup protection to ensure that the module can still operate safely in a degraded manner, and sends the fault type and handling suggestions to the main controller.

[0042] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention.

Claims

1. A mobile energy storage intelligent balancing management system based on a super capacitor module, characterized in that: The system comprises: a plurality of series-connected supercapacitor cells forming an energy storage module; a high-precision synchronous sampling unit for real-time acquisition of the terminal voltage, temperature and leakage current parameters of each supercapacitor cell, and supporting millisecond-level synchronous triggering; a lightweight active balancing unit integrated in the energy storage module, adopting a switched capacitor array topology, and realizing directional energy transfer between adjacent or span cells through a multi-path controllable MOSFET switch network; an edge intelligent management and control module embedded with an adaptive balancing scheduling algorithm, which is based on real-time acquisition data to fuse a load working condition recognition model and a cell aging state prediction model, dynamically generates a feedforward-feedback composite balancing strategy, and triggers preventive balancing operation in advance in any working condition of mobile jolt, pulse discharge or standby drift; and a communication and safety protection interface for interacting with the external mobile energy storage device master control system, and performing graded protection actions when detecting cell overvoltage, abnormal temperature rise or balancing failure. The system as a whole is packaged as a compact module that can be embedded in a vehicle, a portable power supply or emergency equipment, has anti-vibration and wide-temperature-range operation capability, and the balancing process does not depend on external power supply, with energy only circulating and redistributing among the cells in the module.

2. The supercapacitor module-based mobile energy storage intelligent balancing management system according to claim 1, characterized in that: The high-precision synchronous sampling unit ensures time-aligned sampling of the voltage, temperature and leakage current of all supercapacitor cells through a hardware-level synchronous triggering mechanism, avoiding state misjudgment caused by asynchronous sampling when the mobile device experiences high-frequency vibration or acceleration mutation. 3.The super capacitor module based mobile energy storage intelligent balancing management system according to claim 1, characterized in that: The lightweight active balancing unit adopts a switched capacitor array topology without a magnetic core, eliminating traditional inductance elements and reducing volume and weight, while supporting direct or indirect energy transfer between any two cells, suitable for vehicle or portable application scenarios with limited space. 4.The super capacitor module based mobile energy storage intelligent balancing management system according to claim 1, wherein: The MOSFET switch network is configured as a bidirectional conduction structure, allowing energy to flow bidirectionally between adjacent cells and supporting span jumper mode to improve balancing flexibility and response speed under non-uniform aging distribution.

5. The supercapacitor module-based mobile energy storage intelligent balancing management system according to claim 1, characterized in that: The edge intelligent management and control module independently completes working condition recognition and aging state evaluation without external cloud support, and dynamically adjusts the balancing start threshold and execution priority based on the fusion results of the two, realizing localized intelligent decision-making. 6.The super capacitor module based mobile energy storage intelligent balancing management system according to claim 1, wherein: The load working condition recognition model can distinguish four typical scenarios: mobile jolt, pulse discharge, standby drift and steady-state operation, and preset differentiated balancing intervention logic for different scenarios, such as suppressing high-frequency balancing action in jolt working condition to avoid mechanical resonance. 7.The super capacitor module based mobile energy storage intelligent balancing management system according to claim 1, wherein: The cell aging state prediction model based on multi-dimensional degradation feature fusion analysis takes abnormal growth of leakage current, voltage recovery delay and temperature rise sensitivity as aging indicators to identify potential failed cells and guide the preferential allocation of balancing resources. 8.The super capacitor module based mobile energy storage intelligent balancing management system according to claim 1, wherein: The communication and safety protection interface automatically switches to passive balancing mode as a backup protection when detecting balancing failure, and sends fault type and recommended treatment measures to the master control system, ensuring the safety of system degradation operation. 9.The super capacitor module based mobile energy storage intelligent balancing management system according to claim 1, wherein: The overall system packaging structure adopts an integrated anti-vibration bracket and thermal coupling design, which makes the equalization unit, sampling circuit and supercapacitor unit rigidly connected, effectively suppressing the deterioration of electrical contact caused by relative displacement during movement. 10.The super capacitor module based mobile energy storage intelligent balancing management system according to claim 1, wherein: The equalization process relies entirely on the energy stored inside the module, without introducing external power sources or additional energy storage components, and maintains continuous power supply during the equalization period to ensure uninterrupted power supply to the load in mobile application scenarios.

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