A cylindrical battery current, voltage, and temperature probe harness integrated assembly and method

Abstract

The present application relates to battery test equipment and electrical connection field, specifically to a cylindrical battery current, voltage and temperature probe harness integrated assembly; it contains probe fixing base, rigid conductive row, flexible sampling line, probe, conical heat shrink sleeve and phase change thermoplastic elastomer; the assembly constructs inverted V type suspension cavity in the glue injection cavity of fixing base, the welding node of sampling line and probe tail is wrapped by heat shrink sleeve and matched in the suspension cavity, and the remaining gap is filled with phase change elastomer; its core is to use the joule heat generated by the conductive row during testing to make the elastomer expand and become rigidly locked, and when externally pulled, the conical heat shrink sleeve is wedged into the suspension cavity to generate centripetal clamping force; the present application ingeniously combines the flexibility and high rigidity of the material, absorbs assembly stress at room temperature, effectively blocks the stress conduction of mechanical shock to the signal node during work, avoids the micro loosening of the node due to reciprocating motion, and greatly improves the connection reliability in complex environment.

Description

Technical Field

[0001] This invention relates to the field of battery testing equipment and electrical connections, specifically to an integrated assembly and method for a cylindrical battery current, voltage, and temperature probe harness. Background Technology

[0002] When in the specific stages of lithium-ion battery production and testing, the formation, capacity testing, and high-rate charge / discharge processes of cylindrical batteries require high-frequency acquisition of the battery's current, voltage, and temperature using probe assemblies. Due to the compact space within the test cabinet and the large test current, probe modules are typically integrated, converging high-current busbars and voltage sampling lines within a small mounting space.

[0003] To acquire electrical parameters, existing solutions generally employ a split-type press-fit architecture. This involves a mechanical spring or cylinder driving a probe to press against the battery tabs, with the conductive busbar contacting the probe sidewall to transmit the main circuit current. The sampling line is then fixed to the probe tail end via welding or threaded connection. While this solution provides basic conductivity under normal charging and discharging scenarios, its structure is highly dependent on the stability of the mechanical contact, and the sampling node is exposed to a reciprocating vibration environment, making the signal transmission node prone to microscopic loosening. Especially under high-rate current surges, the Joule heating generated at the node causes thermal expansion and contraction at the connection interface, leading to a sharp increase in contact resistance and fluctuations in sampling voltage. This makes it difficult to support continuous monitoring of high-precision indicators and rapid identification of potential faults.

[0004] Therefore, improving the connection reliability and signal transmission accuracy of probe harness integrated components in complex thermal coupling environments has become an urgent technical problem to be solved. Summary of the Invention

[0005] To address the aforementioned technical problems, this invention provides an integrated assembly and method for a cylindrical battery current, voltage, and temperature probe harness. Specifically, the technical solution of this invention is as follows:

[0006] An integrated assembly of current, voltage, and temperature probe harnesses for cylindrical batteries, comprising:

[0007] Probe holder, rigid conductive busbar, flexible sampling line, probe, tapered heat shrink sleeve and phase change thermoplastic elastomer;

[0008] The probe holder is the main support frame, with a stepped guide hole at the bottom and a glue injection cavity at the top that communicates with the guide hole. The inner wall of the glue injection cavity has an inverted V-shaped suspension cavity that is wider at the bottom and narrower at the top.

[0009] The probe body is press-fitted into the guide hole, the probe end extends out of the bottom surface of the probe fixing seat, and the tail extends into the glue injection cavity;

[0010] A rigid conductive busbar is fixed to the side wall of the probe holder, and its extended end passes through the opening in the side wall and is electrically connected to the probe side wall.

[0011] The end of the flexible sampling line is coaxially welded to the tail of the probe to form a signal transmission node;

[0012] A tapered heat shrink sleeve is wrapped around the outside of the signal transmission node, located inside an inverted V-shaped suspension cavity, and forms an axially movable fit with it.

[0013] The phase change thermoplastic elastomer fills the remaining gaps in the injection cavity and the inverted V-shaped suspension cavity, completely encapsulating the conical heat shrink sleeve, the probe tail, and the flexible sampling line. It is configured to expand in volume and maintain high stiffness when the temperature rises, so as to achieve a confined encapsulation and stiffening effect at the component level.

[0014] Optionally, the rigid conductive busbar is fixedly connected to the side wall of the probe holder by an internal hex bolt, wherein the extended end of the rigid conductive busbar is fully laser-welded to the side wall of the probe to transmit a large current and generate Joule heat at the weld.

[0015] Optionally, the outer surface taper of the conical heat shrink sleeve is consistent with the inner wall taper of the inverted V-shaped suspension cavity, wherein the maximum outer diameter of the conical heat shrink sleeve is smaller than the maximum inner diameter of the inverted V-shaped suspension cavity, and the minimum outer diameter of the conical heat shrink sleeve is larger than the inner diameter of the top opening of the inverted V-shaped suspension cavity, so that the conical heat shrink sleeve has an axial floating margin in the inverted V-shaped suspension cavity.

[0016] Optionally, the phase change thermoplastic elastomer is configured to exhibit a low elastic modulus at room temperature to absorb assembly stress generated during welding of the flexible sampling line to the tail of the probe, and to ensure that the probe maintains independent axial floating compliance within the guide hole.

[0017] Optionally, the probe holder is injection molded from insulating resin material.

[0018] A method for operating an integrated assembly of current, voltage, and temperature probes for a cylindrical battery includes the following steps:

[0019] S1: During the room temperature assembly stage, the phase change thermoplastic elastomer in a low elastic modulus state absorbs the assembly internal stress generated when the flexible sampling line is welded to the tail of the probe, so that the probe maintains independent axial floating compliance in the guide hole.

[0020] S2: During the battery bonding test, the external test mechanism presses down the probe holder so that the probe end is pressed against the negative electrode surface of the cylindrical battery. The test cabinet applies a test current to the probe through the rigid conductive busbar to generate Joule heat at the welding point between the rigid conductive busbar and the probe.

[0021] S3: The Joule heat is conducted into the probe holder. After absorbing the heat, the phase change thermoplastic elastomer undergoes nonlinear volume expansion and switches to a rigid locking state, solidifying the flexible sampling line and the rigid conductive busbar into a rigid structure without stress concentration within the probe holder, thereby blocking the transmission of shear stress from external mechanical vibrations to the signal transmission node.

[0022] S4: During the charge-discharge cycle test, the voltage signal transmitted by the flexible sampling line is continuously extracted, and the voltage signal is analyzed in the frequency domain to separate the high-frequency voltage ripple spectrum characteristics.

[0023] S5: Calculate the amplitude change rate of the high-frequency voltage ripple based on the frequency ripple spectrum characteristics. When the amplitude change rate shows an upward trend, adjust the current pulse width output by the test cabinet to excite additional Joule heat output, causing the phase change thermoplastic elastomer to further expand and harden and force the tapered heat shrink sleeve to tighten. When the amplitude change rate does not show an upward trend, keep the current pulse width output by the test cabinet unchanged.

[0024] Optionally, step S3 may be followed by a step to deal with external traction:

[0025] When the external wire harness is pulled, causing the flexible sampling wire to generate an upward pulling force, the pulling force pulls the flexible sampling wire and the conical heat shrink sleeve to move slightly upward, so that the conical surface of the conical heat shrink sleeve wedges into the inner wall of the inverted V-shaped suspension cavity;

[0026] The energy of the pull-out force is converted into a centripetal clamping force perpendicular to both sides of the signal transmission node through the inclined plane geometry. The centripetal clamping force wraps the solder joint between the flexible sampling line and the tail of the probe on the central axis to counteract the eccentric deflection force generated by the pull-out force.

[0027] Optionally, step S5, before adjusting the current pulse width output by the test cabinet, includes:

[0028] Multiply the amplitude change rate by a preset thermodynamic conversion factor to calculate the amount of stiffness compensation that is currently missing in the structure.

[0029] The required Joule heat increment can be derived from the stiffness compensation amount.

[0030] The amplitude of the high-frequency voltage ripple is positively correlated with the degree of slippage of the microscopic contact surface inside the signal transmission node.

[0031] Optionally, the specific operation of adjusting the current pulse width output by the test cabinet in step S5 is as follows:

[0032] Without changing the average test current, an additional Joule thermal output is excited by a transient wide pulse as the Joule thermal increment.

[0033] The Joule thermal increment causes the compressive force in the inverted V-shaped suspension cavity to increase synchronously, actively eliminating the micro-slippage of the signal transmission node until the amplitude of the high-frequency voltage ripple falls back to the initial baseline.

[0034] The present invention has the following beneficial effects:

[0035] 1. This invention effectively improves connection reliability through a combination structure of an inverted V-shaped suspension cavity, a conical heat-shrink sleeve, and a phase change thermoplastic elastomer. During the room temperature assembly stage, the phase change thermoplastic elastomer, which is in a low elastic modulus state, absorbs the internal stress of the assembly, so that the probe maintains independent axial floating compliance. During testing, the Joule heat generated at the welding point between the rigid conductive busbar and the probe causes the phase change thermoplastic elastomer to undergo nonlinear volume expansion and switch to a rigid locking state, solidifying the flexible sampling line and the rigid conductive busbar into a rigid structure without stress concentration within the probe fixing seat. Combined with the centripetal clamping force generated by the conical heat-shrink sleeve wedged into the inverted V-shaped suspension cavity during external pulling, the eccentric deflection force generated by the pull-out force is offset, effectively blocking the transmission of shear stress from external mechanical oscillation to the signal transmission node.

[0036] 2. This invention solves the problem of sampling signal fluctuation during the testing process based on the spectral characteristics of high-frequency voltage ripple. It evaluates the degree of slippage of the micro-contact surface inside the signal transmission node by continuously calculating the amplitude change rate of the high-frequency voltage ripple. When the amplitude change rate shows an upward trend, the current pulse width is adjusted without changing the average test current to excite additional Joule heat output as Joule heat increment, which causes the phase change thermoplastic elastomer to further expand and harden and forces the conical heat shrink sleeve to tighten. This causes the extrusion pressure in the inverted V-shaped suspension cavity to increase synchronously, actively eliminating the micro-slippage of the signal transmission node until the amplitude of the high-frequency voltage ripple falls back to the initial baseline, ensuring the accuracy of signal transmission. Attached Figure Description

[0037] The following drawings, illustrating embodiments of this application, are incorporated herein by reference and are used to understand this application. The drawings illustrate embodiments of this application and their descriptions, serving to explain the principles of this application. In the drawings,

[0038] Figure 1 This is a schematic diagram of the overall structure of the device;

[0039] Figure 2 This is a schematic diagram of the internal structure of the probe holder of the device;

[0040] Figure 3 This is a schematic diagram of the device's probe structure;

[0041] Figure 4 This is a schematic diagram of the guide hole structure of the device;

[0042] Figure 5 This is a flowchart of the method of the present invention.

[0043] In the figure: 100, probe holder; 110, guide hole; 120, glue injection cavity; 130, inverted V-shaped suspension cavity; 140, side wall opening; 200, rigid conductive bar; 210, hexagon socket head cap screw; 300, flexible sampling line; 310, signal transmission node; 400, probe; 410, detection end; 420, tail; 500, tapered heat shrink sleeve; 600, phase change thermoplastic elastomer. Detailed Implementation

[0044] In the following description, numerous specific details are set forth to provide a more thorough understanding of this application. However, it will be apparent to those skilled in the art that embodiments of this application may be practiced without one or more of these details. In other instances, certain technical features well-known in the art have not been described to avoid confusion with embodiments of this application.

[0045] Example 1:

[0046] like Figure 1 and Figure 2 As shown, an integrated assembly of current, voltage, and temperature probe harnesses for cylindrical batteries includes:

[0047] The components include a probe holder 100, a rigid conductive busbar 200, a flexible sampling line 300, a probe 400, a tapered heat shrink sleeve 500, and a phase change thermoplastic elastomer 600.

[0048] The probe holder 100 is the main support frame, with a stepped guide hole 110 at the bottom and a glue injection cavity 120 communicating with the guide hole 110 at the top. The glue injection cavity 120 has an inverted V-shaped suspension cavity 130 that is wider at the bottom and narrower at the top in the middle of its inner wall.

[0049] like Figure 3 and Figure 4 As shown, the probe 400 body is press-fitted into the guide hole 110, the probe end 410 extends out of the bottom surface of the probe fixing seat 100, and the tail 420 extends into the glue injection cavity 120.

[0050] A rigid conductive bus 200 is fixed to the side wall of the probe holder 100, and its extended end passes through the side wall opening 140 and is electrically connected to the side wall of the probe 400.

[0051] The end of the flexible sampling line 300 is coaxially welded to the tail 420 of the probe 400 to form a signal transmission node 310;

[0052] A tapered heat shrink sleeve 500 wraps around the outside of the signal transmission node 310, is located inside the inverted V-shaped suspension cavity 130 and forms an axially movable fit with it;

[0053] The phase change thermoplastic elastomer 600 fills the remaining gap between the injection cavity 120 and the inverted V-shaped suspension cavity 130, completely encapsulating the conical heat shrink sleeve 500, the tail 420 of the probe 400, and the flexible sampling line 300. It is configured to expand in volume and exhibit high stiffness when the temperature rises, so as to achieve the confined encapsulation and stiffening effect at the component level.

[0054] An integrated assembly of current, voltage and temperature probe harnesses for cylindrical batteries can be installed in the probe 400 module of a formation and capacity testing device or a high-rate charge and discharge testing device. The probe mounting base 100 is used to bear the pressure load and define the relative position of each functional component. It is preferably made of heat-resistant insulating resin and its length can be 25mm to 60mm, its width can be 8mm to 20mm, and its height can be 10mm to 30mm.

[0055] The stepped guide hole 110 is used to radially limit and axially guide the probe 400. Its lower section is interference-fitted or clearance-fitted with the body of the probe 400, and its upper section is connected to the glue injection cavity 120, so that the tail 420 of the probe 400 can extend into the glue injection cavity 120.

[0056] The injection cavity 120 can be a columnar cavity or an irregular cavity. An inverted V-shaped suspension cavity 130 is formed in the middle of the injection cavity 120. Its lower-wide and upper-narrow geometry is used to provide axial floating space and a wedge-tight interface for the tapered heat shrink sleeve 500 when it is pulled up.

[0057] The probe 400 can be made of copper alloy, beryllium copper, or nickel-plated copper. The probe end 410 is used to contact the negative electrode surface of the cylindrical battery, and the tail end 420 is used to be coaxially welded to the flexible sampling line 300. The rigid conductive bus 200 bears the main path of the test current and is preferably made of copper or copper alloy plate with a thickness of 0.5 mm to 3 mm. Its extension end passes through the side wall opening 140 of the probe fixing seat 100 and is conductively connected to the side wall of the probe 400, so that the high current path and the voltage sampling path converge at the probe 400 body.

[0058] The flexible sampling line 300 can be a multi-strand tinned copper wire or a thin-diameter highly flexible wire, with a conductor cross-sectional area of ​​0.03 mm² to 0.5 mm². After the insulation layer is removed from its end, it is coaxially welded to the tail 420 of the probe 400 to form a signal transmission node 310.

[0059] The coaxial welding is such that the conductor extension of the flexible sampling line 300 is basically coincident with the center line of the tail 420 of the probe 400, thereby reducing the additional bending moment generated on the weld point under the off-center load condition;

[0060] A tapered heat shrink sleeve 500 is wrapped around the outside of the signal transmission node 310. It can be made of irradiated cross-linked polyolefin, fluorinated heat shrink material or double-wall heat shrink material. After being heated and shrunk, it fits the shape of the solder joint while maintaining the tapered shape of its outer surface to match the tapered shape of the inner wall of the inverted V-shaped suspension cavity 130.

[0061] The phase change thermoplastic elastomer 600 can be a composite material of thermoplastic polyurethane-based elastomer, styrene-based thermoplastic elastomer and micro-expansion filler, wherein the micro-expansion filler is preferably a thermally expandable microcapsule or expandable graphite, and the mass fraction of the micro-expansion filler in the composite material is 5% to 20%; or an elastic encapsulating material with thermal expansion stiffening properties can be used to fill the remaining gap between the injection cavity 120 and the inverted V-shaped suspension cavity 130, allowing the flexible sampling line 300 to bend slightly at room temperature, and to expand in volume and increase the constraint stiffness when subjected to high temperature or Joule heating;

[0062] Compared to the existing structure where the rigid conductive busbar 200 and the flexible sampling line 300 directly merge at a single welding point, this structure, through the combination of the inverted V-shaped suspension cavity 130, the conical heat shrink sleeve 500 and the phase change thermoplastic elastomer 600, respectively configures the flexibility required in the assembly stage and the high stiffness required in the flow stage under different temperature and stress conditions, thereby reducing the risk of shear fatigue at the welding point at the rigid-flexible interface.

[0063] The volume expansion and high stiffness state that occur when the temperature rises are used to characterize the confined encapsulation stiffening effect at the component level, and are not limited to the intrinsic elastic modulus of the encapsulation material necessarily increasing independently in the free state.

[0064] More specifically, after the phase change thermoplastic elastomer 600 absorbs the heat from the weld between the rigid conductive busbar 200 and the probe 400, it expands in volume. On the other hand, this expansion is jointly restricted by the side wall of the injection cavity 120, the inner wall of the inverted V-shaped suspension cavity 130, the outer surface of the conical heat shrink sleeve 500, and the outer periphery of the probe 400 tail 420 and the flexible sampling line 300, thereby forming additional contact pressure and encapsulation pre-tightening force in the confined space.

[0065] Since the additional contact pressure suppresses the relative displacement between the tapered heat shrink sleeve 500, the tail 420 of the probe 400 and the flexible sampling line 300, the overall stress effect of the component is manifested as an increase in equivalent stiffness, enhanced shear resistance of nodes and improved resistance to fretting.

[0066] The high-rigidity state is the overall constraint state formed after the coupling effect of thermal expansion and cavity constraint. The encapsulation body generates a pressing effect in the confined space, which reduces the displacement degree of freedom around the signal transmission node 310 and reduces the risk of solder joint fatigue and loosening.

[0067] The rigid conductive bus 200 is fixedly connected to the side wall of the probe holder 100 by an internal hex bolt 210. The extension end of the rigid conductive bus 200 is connected to the side wall of the probe 400 by laser full welding to transmit large current and generate Joule heat at the welding point.

[0068] When the rigid conductive busbar 200 is fixedly connected to the side wall of the probe mounting base 100 by the internal hexagon bolts 210, metal threaded parts can be pre-embedded in the side wall of the probe mounting base 100 or formed threaded holes can be directly set. The number of internal hexagon bolts 210 can be two, the thread specification can be M2 to M4, and the bolt tightening torque can be 0.15 N·m to 1.2 N·m, so as to ensure that the rigid conductive busbar 200 does not loosen under repeated pressing and vibration conditions;

[0069] The extended end of the rigid conductive busbar 200 passes through the side wall opening 140 and abuts against the outer periphery of the side wall of the probe 400. The laser full welding is a continuous distribution of the weld seam along the contact boundary between the extended end of the conductive busbar and the side wall of the probe 400, so that the welding resistance and local hot spots are more uniformly distributed.

[0070] Laser welding can use pulsed fiber lasers or continuous fiber lasers. The single-point energy can be set from 0.5J to 8J depending on the plate thickness and the thermal conductivity of the material. The weld width can be from 0.2mm to 1.0mm.

[0071] This connection method forms a low-resistance high-current transmission path on the one hand, and a controlled Joule heat source is formed in the welding area when the test current passes through on the other hand. The Joule heat source is close to the spatial position of the glue injection cavity 120 and the inverted V-shaped suspension cavity 130, so that heat can be conducted along the probe 400 body and the extension end of the conductive bus to the phase change thermoplastic elastomer 600.

[0072] Compared with flow passage structures using press-fit plates or separate connectors, the bolt-fixed and laser-welded solution maintains stable conductivity between the conductive busbar and the probe 400, and provides a stable thermal input position that can drive the phase change thermoplastic elastomer 600 to undergo state changes, thereby providing repeatable thermal triggering conditions for subsequent stiffening and locking.

[0073] The outer surface taper of the tapered heat shrink sleeve 500 is consistent with the inner wall taper of the inverted V-shaped suspension cavity 130. The maximum outer diameter of the tapered heat shrink sleeve 500 is smaller than the maximum inner diameter of the inverted V-shaped suspension cavity 130, and the minimum outer diameter of the tapered heat shrink sleeve 500 is larger than the inner diameter of the top opening of the inverted V-shaped suspension cavity 130, so that the tapered heat shrink sleeve 500 has axial floating margin within the inverted V-shaped suspension cavity 130.

[0074] The mating relationship between the tapered heat shrink sleeve 500 and the inverted V-shaped suspension cavity 130 is used to convert the upward pull load into a radial clamping load around the signal transmission node 310. Specifically, the outer surface of the tapered heat shrink sleeve 500 can be designed as a frustum, with a cone angle of 10 to 40 degrees. The inner wall cone angle of the inverted V-shaped suspension cavity 130 is set accordingly, and the angular deviation between the two is preferably controlled within 2 degrees to reduce eccentric contact and local interference wear.

[0075] A radial gap of 0.1 mm to 1.0 mm can be set between the maximum outer diameter of the tapered heat shrink sleeve 500 and the maximum inner diameter of the inverted V-shaped suspension cavity 130. A stop difference of 0.05 mm to 0.5 mm can be set between the minimum outer diameter of the tapered heat shrink sleeve 500 and the inner diameter of the top opening.

[0076] The above dimensional relationship allows the tapered heat shrink sleeve 500 to float slightly axially within the inverted V-shaped suspension cavity 130 in a non-tensioned state, avoiding the direct application of the initial internal stress of the wire harness to the solder joint during assembly;

[0077] When the flexible sampling line 300 is subjected to an upward pulling force, the tapered heat shrink sleeve 500 contacts the inner wall of the inverted V-shaped suspension cavity 130 during the axial upward movement. The inclined contact converts the axial component force into a radial clamping force.

[0078] Since the radial clamping force is distributed circumferentially around the signal transmission node 310, it has an axial holding effect on the solder joints at the tail 420 of the flexible sampling line 300 and the probe 400, reducing the bending stress at the root of the solder joints caused by the external off-center load.

[0079] This geometric relationship differs from the method of using only straight tube heat shrink tubing for encapsulation. Straight tube heat shrink tubing mainly bears frictional resistance in the upward pulling state, making it difficult to form an effective self-reinforcing clamping force. However, the combination of tapered heat shrink sleeve 500 and inverted V-shaped suspension cavity 130 increases the clamping force synchronously when the force increases, thus improving the pull-out resistance and deflection resistance within a limited space.

[0080] The phase change thermoplastic elastomer 600 is configured to exhibit a low elastic modulus at room temperature to absorb the assembly internal stress generated when the flexible sampling line 300 is welded to the tail 420 of the probe 400, and to ensure that the probe 400 maintains independent axial floating compliance within the guide hole 110.

[0081] The mechanical properties of the phase change thermoplastic elastomer 600 change with temperature. It maintains a low elastic modulus at room temperature to allow the necessary micro-displacement of the wire harness and probe 400. After the temperature rises, the volume expands and the overall restraint capability is improved. The room temperature state can be defined as 15℃ to 35℃, and the low elastic modulus can be 0.1MPa to 20MPa.

[0082] The material can be filled into the injection cavity 120 and the inverted V-shaped suspension cavity 130 by hot melt injection, low-pressure potting or secondary encapsulation. The potting amount is to completely wrap the conical heat shrink sleeve 500, the tail 420 of the probe 400 and the flexible sampling line 300.

[0083] After the flexible sampling line 300 and the probe 400 tail 420 are welded together, there is often assembly internal stress around the weld point caused by wire pre-bending, manual positioning deviation, and cooling shrinkage differences.

[0084] The flexible deformation of the phase change thermoplastic elastomer 600 at room temperature can provide a buffer volume around the solder joint, so that the flexible sampling line 300 forms a natural bending radius in the transition section entering the glue injection cavity 120, reducing the fixed constraint at the root of the solder joint.

[0085] At the same time, when the probe 400 body is located in the guide hole 110, it still needs to maintain independent axial floating compliance so that the displacement of the probe 400 itself can absorb the battery height tolerance and clamping error when pressing the negative terminal of the battery.

[0086] If the stiffness of the encapsulation material is too high at room temperature, the tail 420 of the probe 400 and the flexible sampling line 300 will be excessively held, resulting in limited axial travel of the probe 400 and uneven distribution of contact pressure. By configuring the phase change thermoplastic elastomer 600 to a low modulus state at room temperature, both the stress release after welding and the compressive properties of the probe 400 can be met at the same time.

[0087] The probe holder 100 is injection molded from insulating resin material;

[0088] When the probe holder 100 is injection molded from insulating resin material, polyphenylene sulfide, liquid crystal polymer, polyamide with glass fiber, polycarbonate or their blended modified materials can be selected. The volume resistivity is preferably greater than 10 to the power of 12 Ω·cm, and the heat distortion temperature is preferably higher than 120℃ to adapt to the local temperature rise during the high current test process.

[0089] Injection molding can directly form stepped guide holes 110, injection cavity 120, inverted V-shaped suspension cavity 130 and side wall openings 140 through which rigid conductive busbar 200 passes on a single part structure, reducing subsequent machining processes and improving the coaxiality and positional accuracy between functional cavities.

[0090] The axial deviation between the guide hole 110 and the glue injection cavity 120 is preferably no greater than 0.1mm, and the deviation between the inverted V-shaped suspension cavity 130 and the central axis of the glue injection cavity 120 is preferably no greater than 0.15mm, so as to ensure that the tapered heat shrink sleeve 500 can be wedged tightly in the predetermined direction after being stretched.

[0091] The use of insulating resin material also provides electrical isolation when the rigid conductor 200, probe 400 and flexible sampling line 300 are arranged in close proximity, reducing the risk of short circuit to the voltage sampling path from the high current path.

[0092] Compared with the structure of adding an insulating bushing to a metal base, the integral injection molding of insulating resin can reduce the number of assembly interfaces, reduce dimensional drift caused by the difference in thermal expansion coefficients of multiple material contact surfaces, and help maintain the long-term positional stability between the guide hole 110 and the injection cavity 120.

[0093] Example 2:

[0094] like Figure 5 As shown, a method for operating an integrated assembly of current, voltage, and temperature probes for a cylindrical battery includes the following steps:

[0095] S1: During the room temperature assembly stage, the phase change thermoplastic elastomer 600 in a low elastic modulus state absorbs the assembly internal stress generated when the flexible sampling line 300 is welded to the tail 420 of the probe 400, so that the probe 400 maintains independent axial floating compliance in the guide hole 110.

[0096] S2: During the battery crimping test, the external test mechanism presses down the probe fixing seat 100, so that the probe end 410 of the probe 400 presses against the negative electrode surface of the cylindrical battery. The test cabinet applies test current to the probe 400 through the rigid conductive bus 200 to generate Joule heat at the welding point between the rigid conductive bus 200 and the probe 400.

[0097] S3: Joule heat is conducted into the probe holder 100. After absorbing heat, the phase change thermoplastic elastomer 600 undergoes nonlinear volume expansion and switches to a rigid locking state, solidifying the flexible sampling line 300 and the rigid conductive busbar 200 into a rigid structure without stress concentration within the probe holder 100, thereby blocking the transmission of shear stress from external mechanical oscillations to the signal transmission node 310.

[0098] S4: During the charge-discharge cycle test, the voltage signal transmitted by the flexible sampling line 300 is continuously extracted, and the voltage signal is analyzed in the frequency domain to separate the high-frequency voltage ripple spectrum characteristics.

[0099] S5: Calculate the amplitude change rate of high-frequency voltage ripple based on the spectral characteristics of high-frequency voltage ripple. When the amplitude change rate shows an upward trend, adjust the current pulse width output by the test cabinet to excite additional Joule heat output, causing the phase change thermoplastic elastomer 600 to further expand and harden and forcing the tapered heat shrink sleeve 500 to tighten. When the amplitude change rate does not show an upward trend, keep the current pulse width output by the test cabinet unchanged.

[0100] In step S1, after the probe 400 is pressed into the guide hole 110, the flexible sampling line 300 is coaxially welded to the tail 420 of the probe 400, and then the tapered heat shrink sleeve 500 is shrunken to cover the outside of the weld point, and the phase change thermoplastic elastomer 600 is filled into the glue injection cavity 120 and the inverted V-shaped suspension cavity 130.

[0101] At this time, the ambient temperature is maintained between 15℃ and 35℃. The phase change thermoplastic elastomer 600 maintains a low elastic modulus state. The section of the flexible sampling line 300 entering the injection cavity 120 can form a natural bending length of 0.5mm to 10mm according to the direction of the wire. The shrinkage difference and assembly deviation generated by welding cooling are absorbed by the deformation of the phase change thermoplastic elastomer 600. The probe 400 can retain an axial floating stroke of 0.2mm to 3mm in the guide hole 110.

[0102] In step S2, the external testing mechanism can use a cylinder, electric cylinder, or cam head to apply downward pressure. The pressure displacement can be 0.5mm to 5mm, so that the probe end 410 of the probe 400 establishes stable contact with the surface of the negative electrode of the cylindrical battery. The contact force can be 0.5N to 8N. The testing cabinet applies a test current to the probe 400 through the rigid conductive busbar 200. The test current can be set from 1A to 100A according to the battery specifications. Since there is a limited resistance at the welding point between the rigid conductive busbar 200 and the probe 400, repeatable Joule heating is generated in this area.

[0103] In step S3, Joule heat is transferred to the probe holder 100 via the probe 400 and the conductive busbar. After the phase change thermoplastic elastomer 600 reaches its material response temperature range, it undergoes nonlinear volume expansion, the modulus increases, and it forms a compression constraint on the space around the tapered heat shrink sleeve 500, the tail 420 of the probe 400, and the flexible sampling line 300.

[0104] The rigid body structure without stress concentration consists of the flexible sampling line 300, the tapered heat shrink sleeve 500, the tail 420 of the probe 400, and the adjacent rigid conductive bus 200, which are all locally constrained under the coverage of the phase change thermoplastic elastomer 600. Their relative displacement is significantly reduced, thereby reducing the amplitude of shear displacement transmitted to the solder joint by mechanical vibration.

[0105] In step S4, the test cabinet or independent sampling module continuously acquires the voltage signal on the flexible sampling line 300. The sampling frequency can be from 10kHz to 5MHz. The acquisition window can be synchronized with the charging and discharging pulse period. Discrete Fourier transform, fast Fourier transform or equivalent spectrum analysis is performed on the acquired time domain signal to separate the high-frequency voltage ripple spectrum characteristics.

[0106] In step S5, the amplitude of the high-frequency voltage ripple within multiple consecutive sampling windows is compared to obtain the amplitude change rate;

[0107] The amplitude change rate shows an upward trend, indicating that the micro-motion at the signal transmission node 310 has increased. The test cabinet adjusts the current pulse width without changing the average test current requirement to increase short-time heat input, causing the phase change thermoplastic elastomer 600 to expand and harden further, while forcing the contact compression between the conical heat shrink sleeve 500 and the inverted V-shaped suspension cavity 130 to increase.

[0108] If the amplitude change rate does not show an upward trend, the current current pulse width is maintained. Through this method, the mechanical stability of the structure can be adjusted according to the change in heat input during the test, thereby reducing the impact of loose solder joints on the accuracy of voltage measurement.

[0109] The judgment process in steps S4 and S5 can be refined in sequence as follows: First, the original voltage time domain signal output by the flexible sampling line 300 is used as input data. The original signal in each sampling window is processed to remove the DC component, and then the ripple amplitude value in the preset high frequency band is extracted.

[0110] The preset high-frequency band is used to characterize the high-frequency components caused by solder joint micro-movement, rapid fluctuation of contact resistance and parasitic inductance disturbance, and preferably avoids the low-frequency main components of normal battery charging and discharging as well as the power frequency interference band.

[0111] The high-frequency voltage ripple amplitude obtained in the current sampling window is compared with the previous sampling window, the two previous sampling windows, or the initial reference value after assembly to form a continuous time series. The initial reference value is preferably obtained by collecting 3 to 20 sampling windows and taking the average value when the probe 400 assembly is completed, the first crimping is stable, and the wire harness is not disturbed by external factors. It is used to represent the reference ripple level when the node is in a normal and stable state.

[0112] An upward trend in amplitude change rate occurs when the high-frequency voltage ripple amplitude change rate is greater than zero for at least two consecutive sampling windows, or when the current amplitude exceeds the preset tolerance band relative to the initial reference value. The preset tolerance band can be set to 5% to 15% of the initial reference value. The purpose of using continuous window judgment is to avoid misjudgment caused by single sampling noise, transient contact jitter, or external electromagnetic interference.

[0113] If only a single window is abnormal and subsequent windows recover to within the tolerance band, it is determined to be an occasional disturbance and will not trigger pulse width adjustment; if multiple windows rise continuously, or although they do not rise continuously but are always above the upper limit of the tolerance band, it is determined to be insufficient node stiffness or that the micro-motion has a tendency to accumulate and expand, and will enter the thermal compensation control in step S5.

[0114] Therefore, step S4 outputs the high-frequency voltage ripple amplitude and its time variation sequence, and step S5 takes this sequence as input and outputs the control result of whether to maintain the current pulse width or whether to enter the heating compensation action.

[0115] The frequency domain analysis and thermal compensation judgment involved in steps S4 and S5 can be regarded as a functional model for evaluating node stability. This model uses the collectable voltage signal changes to identify whether the signal transmission node 310 has experienced a decrease in stability caused by micro-motion, relaxation or contact state fluctuations. Logically, this model includes at least a signal preprocessing unit, a frequency band feature extraction unit, a trend determination unit and a thermal compensation execution unit.

[0116] The signal preprocessing unit receives the raw time-domain voltage signal output from the flexible sampling line 300 and uses it to remove the DC component and low-frequency components directly related to the main test condition. In this embodiment, the signal preprocessing unit uses a first-order digital high-pass filter model to filter the time-domain signal, and its discrete-time difference calculation logic is expressed as follows:

[0117]

[0118] in, For the preprocessed first Voltage signal at each sampling point For the first The original time-domain voltage signal of each sampling point The filter coefficients are determined by the cutoff frequency and the sampling period. For the preprocessed first Voltage signal at each sampling point For the first The original time-domain voltage signal of each sampling point This is the sampling point number; its calculation formula is:

[0119]

[0120] in, This is the high-pass cutoff frequency of the filter. The sampling period is The value is pi; the frequency band feature extraction unit receives the preprocessed signal and uses it to extract the ripple amplitude within the preset high-frequency band; the trend determination unit compares the current amplitude with the historical amplitude, the initial reference value, and the tolerance band to output the judgment result of whether the node's stable state has deteriorated;

[0121] The thermal compensation execution unit selects to maintain the existing pulse width or increase the pulse width based on the judgment result to change the heat input at the weld. When there is a slight slippage, contact pressure change or parasitic parameter disturbance at the interface near the weld point, it will cause rapid fluctuations in contact resistance and parasitic inductance.

[0122] These rapid fluctuations, when superimposed on the sampling voltage, manifest as enhanced high-frequency ripple in the frequency domain. Therefore, the changes in the high-frequency ripple characteristics can be used to inversely determine whether the local constraints of the node are insufficient, and further stiffening can be achieved by using controlled Joule thermal drive of the encapsulation structure.

[0123] The rigid locking state is a constrained stable state in which the equivalent displacement degrees of freedom are significantly compressed, and small elastic deformation is retained between the flexible sampling line 300, the rigid conductive bus 200 and the encapsulation.

[0124] In steps S3 to S5: the heat input increases the restricted expansion and contact compression of the encapsulation area, thereby reducing the relative displacement of the nodes; the reduction in the relative displacement of the nodes causes the high-frequency ripple caused by the micro-motion to fall back; whether the ripple falls back is used as the effective feedback basis for thermal compensation.

[0125] More specifically, the frequency domain analysis in step S4 can be achieved using discrete Fourier transform, and the high-frequency voltage ripple amplitude... By using the preset frequency band The voltage amplitude spectrum within the range is extracted, and the amplitude change rate is obtained. The calculation logic is as follows:

[0126]

[0127] in, The rate of change of amplitude, This represents the high-frequency voltage ripple amplitude within the current sampling window. This represents the high-frequency voltage ripple amplitude of the previous sampling window. The sampling window number. The time interval between sampling windows; and These are the lower and upper frequency limits of the preset frequency band, respectively; this structured calculation process ensures the programmable extraction of ripple features;

[0128] Step S3 is followed by a step to deal with external pulling: when the external wire harness is pulled, causing the flexible sampling wire 300 to generate an upward pulling force, the pulling force pulls the flexible sampling wire 300 and the conical heat shrink sleeve 500 to move slightly upward, so that the conical surface of the conical heat shrink sleeve 500 weds into the inner wall of the inverted V-shaped suspension cavity 130.

[0129] The energy of the pulling force is converted into a centripetal clamping force perpendicular to both sides of the signal transmission node 310 through the inclined plane geometry. The centripetal clamping force wraps the solder joint of the flexible sampling line 300 and the tail 420 of the probe 400 on the central axis to counteract the eccentric deflection force generated by the pulling force.

[0130] After the rigid locking state is formed in step S3, if the flexible sampling line 300 is subjected to an upward pulling force due to equipment operation, manual maintenance, or wiring harness tidying, the pulling force is transmitted to the tapered heat shrink sleeve 500 through the flexible sampling line 300. Since the tapered heat shrink sleeve 500 has axial floating margin in the inverted V-shaped suspension cavity 130, the tapered heat shrink sleeve 500 will move slightly upward along the central axis, and the displacement can be 0.05mm to 1mm.

[0131] When the outer conical surface of the tapered heat shrink sleeve 500 contacts the inner wall of the inverted V-shaped suspension cavity 130, the axial tensile force is decomposed into a centripetal clamping force acting in the normal direction along the cavity wall and a frictional force acting in the tangential direction along the contact interface, wherein the centripetal clamping force acts around the signal transmission node 310.

[0132] The centripetal clamping force keeps the solder joint area between the flexible sampling line 300 and the tail 420 of the probe 400 as close as possible to the central axis of the probe 400, reducing the lateral displacement of the flexible sampling line 300 caused by pull-out eccentricity.

[0133] The eccentric bending force is the bending load formed at the root of the solder joint when the tensile direction of the flexible sampling line 300 deviates from the axis of the probe 400.

[0134] Through the geometric force-enhancing interface formed by the conical surface and the inverted V-shaped suspension cavity 130, a portion of the bending load originally acting on the root of the weld point can be transferred to a clamping load distributed around the weld point, thereby reducing the stress concentration at the weld point.

[0135] This step can occur passively during the test without the need for additional driving components, and is suitable for situations where the wire harness moves frequently in the multi-channel probe 400 module.

[0136] Before step S5, which involves adjusting the current pulse width output by the test cabinet, the following steps are included:

[0137] Multiply the amplitude change rate by the preset thermodynamic conversion factor to calculate the amount of stiffness compensation that is currently missing in the structure.

[0138] The required Joule heat increment is derived from the stiffness compensation amount; among which, the amplitude of the high-frequency voltage ripple is positively correlated with the degree of slippage of the micro-contact surface inside the signal transmission node 310.

[0139] Before adjusting the current pulse width in step S5, a conversion relationship between high-frequency voltage ripple and the degree of structural micro-motion can be established; the amplitude of the high-frequency voltage ripple can be the peak value, root mean square value or weighted integral value within a preset frequency band, which can be from 1kHz to 500kHz.

[0140] By differentially processing the high-frequency voltage ripple amplitude within several consecutive sampling windows and dividing it by the corresponding time interval, the amplitude change rate can be obtained, which can be expressed in mV / s or % / s. The preset thermodynamic conversion coefficient is used to map the amplitude change rate to the stiffness compensation amount of the structural deficiency. This coefficient can be obtained through prototype calibration.

[0141] The calibration method can be as follows: under the condition that the pulling disturbance, vibration disturbance and temperature rise are known, record the rate of change of high frequency voltage ripple amplitude under different encapsulation stiffness, and establish the correspondence between the rate of change and the target additional constraint stiffness;

[0142] The stiffness compensation amount can be expressed as N per mm or equivalent modulus increment; based on the material thermal expansion response curve and modulus temperature curve of phase change thermoplastic elastomer 600, the stiffness compensation amount can be further converted into the required Joule heat increment.

[0143] The conversion logic is based on material response characteristics. By introducing a conversion constant μ that integrates the material's thermal expansion coefficient and the cavity constraint stiffness, an explicit transfer function between heat input and target stiffness is established to achieve precise quantitative control. Its specific back-calculation logic is expressed as follows:

[0144]

[0145] in, For the required Joule heat increment, To integrate the conversion constants of material thermal expansion coefficient and cavity constraint stiffness, This is the stiffness compensation amount; thus completing the accurate solution from the degree of insufficient structural constraints to the thermodynamic control variables;

[0146] The magnitude of the high-frequency voltage ripple is positively correlated with the degree of slippage of the micro-contact surface inside the signal transmission node 310. That is, when the solder joint or its adjacent conductive contact interface slips slightly, the contact resistance and parasitic inductance fluctuate rapidly. This fluctuation is superimposed on the sampling voltage to form a high-frequency ripple. Therefore, the high-frequency voltage ripple can be used as a characterization parameter of the node's stability.

[0147] By introducing thermodynamic conversion coefficients and Joule heat increment back-calculation steps, subsequent pulse width adjustments have clear input and output values, avoiding the risk of overheating caused by increasing the current pulse based solely on experience.

[0148] The amplitude change rate can be calculated as follows: using the high-frequency voltage ripple amplitude obtained within the current sampling window. High-frequency voltage ripple amplitude compared to the previous sampling window As input, combined with the time interval between two sampling windows The rate of change of amplitude is obtained as follows:

[0149]

[0150] in, The absolute amplitude change rate, This represents the high-frequency voltage ripple amplitude obtained within the current sampling window. This represents the high-frequency voltage ripple amplitude of the previous sampling window. The time interval between two sampling windows;

[0151] If expressed as % / s, the numerator is then divided by the initial baseline amplitude or the rolling reference amplitude; the above processing obtains the rate of change by acquiring the amplitude and comparing adjacent windows.

[0152] The preset thermodynamic conversion factor is the target stiffness compensation requirement corresponding to the unit amplitude change rate, which is used to convert the degree of electrical signal abnormality into the degree of structural constraint insufficiency.

[0153] This coefficient is not set arbitrarily, but is determined in advance through prototype testing. Specifically, several probe 400 component prototypes can be selected first, and under the conditions of known wire harness tension, vibration intensity and ambient temperature, different levels of additional heat input can be applied to make the phase change thermoplastic elastomer 600 reach different degrees of expansion.

[0154] Record the rate of change of high-frequency voltage ripple amplitude and the corresponding node displacement, pull-out force or equivalent stiffness of the encapsulation body in each state; then select the minimum stiffness value that makes the high-frequency ripple fall back to the initial baseline or tolerance range, and establish a one-to-one correspondence table or segmented correspondence table between the rate of change of amplitude and the required stiffness compensation.

[0155] In actual use, the stiffness compensation amount is first obtained by looking up the table from the currently detected amplitude change rate, and then the corresponding Joule heat increment is obtained by looking up the table from the material response curve.

[0156] The required Joule heat increment is derived from the stiffness compensation amount. Specifically, the additional constraint capacity required to reach the target stable state from the current node stable state is first determined. Then, based on the volume expansion and modulus increase of the phase change thermoplastic elastomer 600 at different temperature rises, the minimum heat input level that can make up for the gap in the additional constraint capacity is selected.

[0157] The minimum heat input level is preferably set in a graded manner, such as three or more levels: low, medium, and high, so that the control strategy can be easily implemented in the test cabinet; if the stiffness compensation obtained from the table is lower than the first threshold, there is no need to add Joule heat.

[0158] If the value is between the first threshold and the second threshold, low-level thermal compensation is invoked; if the value is above the second threshold, medium or high-level thermal compensation is invoked. The first and second thresholds can also be obtained through prototype calibration. Their purpose is to avoid frequent adjustment of the pulse width under slight disturbances and to prevent the introduction of unnecessary additional heat in a sufficiently stable state.

[0159] Thermodynamic conversion factors are transformation parameters in the thermal compensation calculation model, used to convert the degree of structural constraint insufficiency into thermal input control quantities executed by the test cabinet; the model can be logically divided into three sequentially connected parts:

[0160] The first part is the anomaly characterization part, which receives the high-frequency ripple amplitude change rate, the deviation of the current amplitude from the initial reference value, and the number of consecutive anomaly windows output by step S4, and is used to form the anomaly level of the current node.

[0161] The second part is the stiffness requirement conversion part, which receives the anomaly level and combines it with the preset thermodynamic conversion coefficient or lookup table rules to output the target stiffness compensation amount.

[0162] The third part is the heat input reverse calculation part, which receives the target stiffness compensation amount and combines it with the thermal response calibration results of the phase change thermoplastic elastomer 600 to output the required Joule heat increment level or the corresponding pulse width adjustment level.

[0163] Its signal processing flow is as follows: the voltage time domain signal is first extracted into high-frequency ripple characteristics, then converted into node stability anomalies, then converted into target stiffness compensation, and finally converted into executable thermal input control commands.

[0164] The more obvious the node micro-motion, the larger the high-frequency ripple anomaly; the larger the high-frequency ripple anomaly, the larger the gap between the current encapsulation constraint and the target stable state; the larger the constraint gap, the more controlled Joule heating is needed to make the phase change thermoplastic elastomer 600 generate a higher clamping effect in the confined space.

[0165] Under the same test conditions, sampling bandwidth, and component structure, an increase in the amplitude or rate of change of high-frequency voltage ripple leads to an increased risk of microslippage at the corresponding nodes. By setting initial reference values, tolerance bands, continuous window judgment rules, and prototype calibration, occasional fluctuations caused by non-structural factors are filtered out, and a stable mapping relationship from high-frequency ripple to stiffness compensation is established. The thermodynamic conversion coefficient can be defined through a linear proportional correlation model, i.e.:

[0166]

[0167] in, These are preset thermodynamic conversion coefficients; through the above linearization decomposition, the abstract thermodynamic conversion is transformed into directly calculable arithmetic logic;

[0168] To further quantify the thermodynamic conversion factor The value selection logic, in this embodiment, provides a specific set of calibration references: when the ripple amplitude change rate When it is in the range of 0.01 to 0.05 / s, The possible values ​​are The magnitude of N per mm per unit amplitude change rate, and the corresponding stiffness compensation amount is calculated by looking up a table or by linear interpolation.

[0169] Joule heating increment The calculation also needs to be compensated by the surface heat dissipation coefficient of the probe holder 100. By introducing a heat dissipation correction factor, it is ensured that the final generated controlled Joule heat can overcome the heat conduction loss, so that the temperature rise of the phase change thermoplastic elastomer 600 falls precisely within its optimal response temperature range for expansion and stiffening.

[0170] The specific operation of adjusting the current pulse width output by the test cabinet in step S5 is as follows: without changing the average test current, the transient wide pulse is used to excite additional Joule heat output as Joule heat increment; the Joule heat increment causes the extrusion pressure in the inverted V-shaped suspension cavity 130 to increase synchronously, actively eliminating the micro-slippage of the signal transmission node 310 until the amplitude of the high-frequency voltage ripple falls back to the initial baseline.

[0171] After determining the required Joule heat increment, the test cabinet adjusts the pulse width of the output current waveform; constant average test current means that the current-time integral value remains within the predetermined statistical period, meeting the requirements of the battery test specification. For example, the original pulse current is the amplitude. ,cycle Pulse width After adjustment, the amplitude can still be used. The cycle remains the same. The pulse width increases to Meanwhile, compensation control is applied to the pulse interval or other periodic segments within the same statistical period to ensure that the average value does not deviate from the set value.

[0172] Transient wide pulses are used to increase the heat input in the welding area between the rigid conductive busbar 200 and the probe 400 for a short time, so that heat is conducted into the probe holder 100 and the expansion degree of the phase change thermoplastic elastomer 600 is increased.

[0173] As the phase change thermoplastic elastomer 600 expands, the extrusion pressure of the encapsulation body inside the inverted V-shaped suspension cavity 130 on the outer wall of the conical heat shrink sleeve 500 increases, the fit between the conical heat shrink sleeve 500 and the signal transmission node 310 is improved, and the relative displacement around the signal transmission node 310 is further suppressed.

[0174] The active elimination of micro-slip can be achieved by reading the latest high-frequency voltage ripple amplitude at the end of each detection cycle and comparing it with the initial baseline. If it is still higher than the baseline, the pulse width is adjusted by the set increment. If it falls back to the initial baseline or enters the preset tolerance range, the pulse width is stopped and the current output parameters are maintained. The initial baseline can be the average high-frequency voltage ripple amplitude during the initial stable operation of the probe 400 assembly, and the tolerance range can be set to ±5% to ±15% of the baseline.

[0175] By introducing a transient wide pulse without changing the average test current, the battery test conditions remain consistent, while additional heat input is obtained inside the structure to improve the encapsulation stiffness and intracavity extrusion pressure, thereby suppressing the micro-loosening tendency of the signal transmission node 310.

[0176] The pulse width adjustment process in step S5 can be executed in the following order:

[0177] Receive the Joule heat increment demand derived from the reverse calculation and convert the demand into the corresponding pulse width adjustment level; determine whether the average test current in the current test cycle still meets the established test specifications. If it does, prioritize increasing the conduction duration of a single pulse or several consecutive pulses.

[0178] If increasing the pulse width may cause the average test current within the statistical period to deviate from the set value, the pulse interval will be extended synchronously, the conduction time of one or more subsequent pulses will be reduced, or the compensation heat will be distributed to multiple test periods to ensure that the battery test results are consistent with the predetermined operating conditions. Thus, the input of the control system is the current Joule heat increment requirement, the original current waveform parameters and the average test current constraint, and the output is the corrected pulse width and the corresponding interval compensation parameters.

[0179] In this invention, the transient wide pulse excitation of additional Joule thermal output is preferably performed in a graded incremental manner, rather than by increasing the pulse width drastically all at once; specifically, an initial pulse width increment level, a secondary pulse width increment level, and a tertiary pulse width increment level can be set.

[0180] When the high-frequency voltage ripple amplitude only slightly exceeds the initial baseline, the initial pulse width increment setting is called; when the amplitude continues to rise or exceeds the upper limit of the tolerance band by a large margin in multiple consecutive detection cycles, a higher setting is called.

[0181] After each increment, it is preferable to maintain the current increment for 1 to 5 testing cycles to observe whether the ripple amplitude drops back. If the ripple amplitude drops back to the initial baseline or falls within the tolerance range, maintain the current increment and do not continue to increase it.

[0182] If the ripple amplitude does not decrease, then proceed to the next level; this step-by-step incremental logic can reduce overheating, prevent excessive expansion of the phase change thermoplastic elastomer 600, and improve the repeatability of control actions.

[0183] Until the amplitude of the high-frequency voltage ripple falls back to the initial reference line, that is, falls back to the initial reference line itself or falls back to a stable tolerance range set around the initial reference line; the preferred method for obtaining the initial reference line is:

[0184] During the initial stable operation phase of the probe 400 assembly, under conditions of no significant external force interference from the wire harness, no abnormal vibration, and normal contact status, the high-frequency voltage ripple amplitude of multiple detection cycles was continuously collected and the average value was taken.

[0185] The stable tolerance range can be set to ±5% to ±15% of the initial baseline based on the equipment noise level, sampling resolution, and test repeatability. If the ripple amplitude is within this stable tolerance range for 2 to 5 consecutive detection cycles, it is determined that the micro-slippage has been suppressed, and the pulse width should not be increased further. If the pulse width exceeds this stable tolerance range again, the pulse width adjustment process described above should be restarted.

[0186] By clearly defining the baseline acquisition, tolerance determination, and stopping conditions, the control logic for actively eliminating micro-slippage can have clear triggering and termination criteria; the corrected transient pulse width is achieved during the pulse width adjustment in step S5. With Joule heat increment The correspondence follows:

[0187]

[0188] in, This is the corrected transient pulse width. The original pulse width, The current amplitude, The contact resistance at the weld joint; this quantization stepping mechanism makes the operation of actively eliminating micro-slippage clearly executable; when performing the compensation operation with constant average test current, the equal-electric pulse modulation technique is specifically adopted;

[0189] When the pulse width increases from the original value to the corrected value, the test cabinet synchronously calculates and adjusts the pulse turn-off time so that the integral value of current with respect to time, i.e. the total charge, remains constant within a complete monitoring cycle.

[0190] For example, if an increase in pulse width leads to an increase in heat generation per cycle, the average current fluctuation felt by the battery terminal can be controlled within 0.5% by proportionally extending the pulse off-time. This adjustment mechanism decouples the structural stiffness thermal compensation from the battery testing electrochemical environment, ensuring the longitudinal comparability of the test data.

[0191] This application has been described through the above embodiments; however, it should be understood that the above embodiments are for illustrative purposes only and are not intended to limit this application to the described embodiments. Those skilled in the art will understand that many more variations and modifications can be made based on the teachings of this application, and all such variations and modifications fall within the scope of protection claimed in this application.

Claims

1. An integrated assembly of current, voltage, and temperature probe harnesses for a cylindrical battery, characterized in that, include: The probe holder (100), rigid conductive bus (200), flexible sampling line (300), probe (400), tapered heat shrink sleeve (500) and phase change thermoplastic elastomer (600); The probe holder (100) is the main support frame. It has a stepped guide hole (110) at the bottom and a glue injection cavity (120) at the top that communicates with the guide hole (110). The glue injection cavity (120) has an inverted V-shaped suspension cavity (130) that is wider at the bottom and narrower at the top in the middle of its inner wall. The probe (400) body is press-fitted into the guide hole (110), the probe end (410) extends out of the bottom surface of the probe fixing seat (100), and the tail (420) extends into the glue injection cavity (120); A rigid conductive bus (200) is fixed to the side wall of the probe holder (100), and its extended end passes through the side wall opening (140) and is electrically connected to the side wall of the probe (400). The end of the flexible sampling line (300) is coaxially welded to the tail (420) of the probe (400) to form a signal transmission node (310). A tapered heat shrink sleeve (500) wraps around the outside of the signal transmission node (310), is located inside the inverted V-shaped suspension cavity (130), and forms an axially movable fit with it; The phase change thermoplastic elastomer (600) fills the remaining gaps in the injection cavity (120) and the inverted V-shaped suspension cavity (130), completely encapsulating the conical heat shrink sleeve (500), the tail (420) of the probe (400) and the flexible sampling line (300), and is configured to expand in volume and exhibit high stiffness when the temperature rises, so as to achieve the confined encapsulation stiffening effect at the component level.

2. The integrated assembly of cylindrical battery current, voltage, and temperature probe harnesses according to claim 1, characterized in that, The rigid conductive bus (200) is fixedly connected to the side wall of the probe holder (100) by an internal hex bolt (210). The extension end of the rigid conductive bus (200) is connected to the side wall of the probe (400) by laser full welding to transmit a large current and generate Joule heat at the welding point.

3. The integrated assembly of cylindrical battery current, voltage, and temperature probe harnesses according to claim 1, characterized in that, The outer surface taper of the tapered heat shrink sleeve (500) is consistent with the inner wall taper of the inverted V-shaped suspension cavity (130). The maximum outer diameter of the tapered heat shrink sleeve (500) is smaller than the maximum inner diameter of the inverted V-shaped suspension cavity (130), and the minimum outer diameter of the tapered heat shrink sleeve (500) is larger than the inner diameter of the top opening of the inverted V-shaped suspension cavity (130), so that the tapered heat shrink sleeve (500) has an axial floating margin in the inverted V-shaped suspension cavity (130).

4. The integrated assembly of cylindrical battery current, voltage, and temperature probe harnesses according to claim 1, characterized in that, The phase change thermoplastic elastomer (600) is configured to exhibit a low elastic modulus at room temperature to absorb the assembly internal stress generated when the flexible sampling line (300) is welded to the tail (420) of the probe (400) and to ensure that the probe (400) maintains independent axial floating compliance within the guide hole (110).

5. The integrated assembly of cylindrical battery current, voltage, and temperature probe harnesses according to claim 1, characterized in that, The probe holder (100) is injection molded from insulating resin material.

6. A method for operating a cylindrical battery current, voltage, and temperature probe harness integrated assembly, based on the cylindrical battery current, voltage, and temperature probe harness integrated assembly of claim 1, characterized in that, Includes the following steps: S1: During the room temperature assembly stage, the phase change thermoplastic elastomer (600) in a low elastic modulus state absorbs the assembly internal stress generated when the flexible sampling line (300) is welded to the tail (420) of the probe (400), so that the probe (400) maintains independent axial floating compliance in the guide hole (110). S2: During the battery pressing test, the external test mechanism presses down the probe holder (100) so that the probe end (410) of the probe (400) presses against the negative electrode surface of the cylindrical battery. The test cabinet applies a test current to the probe (400) through the rigid conductive bus (200) to generate Joule heat at the welding point between the rigid conductive bus (200) and the probe (400). S3: The Joule heat is conducted into the probe holder (100). After absorbing the heat, the phase change thermoplastic elastomer (600) undergoes nonlinear volume expansion and switches to a rigid locking state, solidifying the flexible sampling line (300) and the rigid conductive bus (200) into a rigid structure without stress concentration within the probe holder (100), thereby blocking the transmission of shear stress from external mechanical vibrations to the signal transmission node (310). S4: During the charge-discharge cycle test, the voltage signal transmitted by the flexible sampling line (300) is continuously extracted, and the voltage signal is analyzed in the frequency domain to separate the high-frequency voltage ripple spectrum characteristics. S5: Calculate the amplitude change rate of the high-frequency voltage ripple based on the frequency ripple spectrum characteristics. When the amplitude change rate is increasing, adjust the current pulse width output by the test cabinet to excite additional Joule heat output, causing the phase change thermoplastic elastomer (600) to further expand and harden and forcing the tapered heat shrink sleeve (500) to tighten. When the amplitude change rate is not increasing, keep the current pulse width output by the test cabinet unchanged.

7. The operating method of the cylindrical battery current, voltage, and temperature probe harness integrated assembly according to claim 6, characterized in that, Following step S3, a step is also included to deal with external traction: When the external wire harness is pulled, causing the flexible sampling line (300) to generate an upward pulling force, the pulling force pulls the flexible sampling line (300) and the conical heat shrink sleeve (500) to move slightly upward, so that the conical surface of the conical heat shrink sleeve (500) weds into the inner wall of the inverted V-shaped suspension cavity (130); The energy of the pulling force is converted into a centripetal clamping force perpendicular to both sides of the signal transmission node (310) through the inclined plane geometry. The centripetal clamping force wraps the solder joint of the flexible sampling line (300) and the tail (420) of the probe (400) on the central axis to counteract the eccentric bending force generated by the pulling force.

8. The operating method of the cylindrical battery current, voltage, and temperature probe harness integrated assembly according to claim 6, characterized in that, Before the step of adjusting the current pulse width output by the test cabinet in step S5, the following steps are included: Multiply the amplitude change rate by a preset thermodynamic conversion factor to calculate the amount of stiffness compensation that is currently missing in the structure. The required Joule heat increment can be derived from the stiffness compensation amount. The amplitude of the high-frequency voltage ripple is positively correlated with the degree of slippage of the micro-contact surface inside the signal transmission node (310).

9. The operating method of the cylindrical battery current, voltage, and temperature probe harness integrated assembly according to claim 8, characterized in that, The specific operation for adjusting the current pulse width output by the test cabinet in step S5 is as follows: Without changing the average test current, an additional Joule thermal output is excited by a transient wide pulse as the Joule thermal increment. The Joule thermal increment causes the compressive force in the inverted V-shaped suspension cavity (130) to increase synchronously, actively eliminating the micro-slippage of the signal transmission node (310) until the amplitude of the high-frequency voltage ripple falls back to the initial baseline.

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