A mobile energy storage charging off-grid self-power supply system with black start capability and a control method thereof
Patent Information
- Application Number
- CN202610581546.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-04-29
- Publication Date
- 2026-08-04
AI Technical Summary
目前的黑启动技术多侧重于大型抽水蓄能或燃气轮机机组，而对于移动式储能系统，其黑启动面临着“逻辑锁定”的困境：当单体欠压触发三级故障后，BMS 为了安全会禁止闭合接触器，导致系统无法对外输出能量，即使电池内部仍存有少量应急电能也无法被提取利用
[0025] 1. This invention achieves system-level safe self-destruction and rapid emergency recovery under the premise of complying with the VDE-AR-E 2510-50 standard through a self-power-off control board architecture, a black-start logic architecture, and a self-power-off logic architecture. It solves the problems of safe self-destruction, low-power standby, and forced wake-up and system reconstruction of mobile energy storage systems under extreme undervoltage conditions and when external power and communication links are lost.
Smart Images
Figure CN122512495A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of distributed energy technology, and in particular relates to a mobile energy storage charging off-grid self-powered system with black start capability and its control method. Background Technology
[0002] With the transformation of the global energy structure and the rapid increase in the number of electric vehicles, mobile energy storage and charging technologies have become key tools for building resilient grids and alleviating the uneven distribution of charging infrastructure. Mobile Energy Storage Systems (MESS) are typically mounted on vehicles and integrate components such as high-voltage lithium batteries, bidirectional power converters (PCS), power-to-discharge (DCDC) modules, battery management systems (BMS), and thermal management systems. These systems face a series of technical challenges in long-term storage, remote relocation, or off-grid operation.
[0003] Firstly, the battery management system (BMS), as the core control unit, has its own power consumption, which is one of the main causes of excessive battery discharge. Although the BMS's standby current is small when the system is off or in hibernation mode, prolonged self-discharge can cause the cell voltage to drop below the physical damage threshold when there is no external power supply and the battery is at a low state of charge (SOC) critical value. According to international safety standards such as VDE-AR-E 2510-50, when the voltage of a lithium iron phosphate cell drops to around 2.0V, the system must take thorough disconnection measures to prevent thermal runaway or cell failure. Traditional hibernation modes often cannot completely eliminate leakage current, and under extreme undervoltage conditions, if the system cannot physically disconnect the high-voltage circuit and auxiliary power supply, it will lead to permanent damage to the battery cluster.
[0004] Secondly, restarting and establishing an internal microgrid (i.e., black start) for mobile energy storage systems during large-scale power outages or in complete darkness (i.e., without grid support and after the system shuts down for self-protection) is a recognized challenge in the industry. Current black start technologies primarily focus on large-scale pumped-storage hydroelectric or gas turbine units. However, for mobile energy storage systems, black start faces a "logic lockout" dilemma: when a single cell undervoltage triggers a level 3 fault, the BMS will prevent the contactor from closing for safety, preventing the system from outputting energy, even if a small amount of emergency energy remains inside the battery. Furthermore, if the communication link between the domain controller and the BMS fails, the BMS often becomes deadlocked because it cannot receive the closing command, causing the emergency power supply task to fail.
[0005] Existing mobile energy storage vehicles mostly use diesel generators as black start auxiliary power sources, which not only increases the size and weight of the vehicles, but also brings problems such as high noise, high emissions, and complex fuel maintenance. Although some solutions attempt to use UPS or small-capacity starter batteries for black start, their hardware circuit design is complex and costly, and it is difficult to meet the stringent requirements of VDE certification for "self-disconnecting" deep discharge protection.
[0006] Therefore, there is an urgent need in this field for a mobile energy storage charging off-grid self-powered system and its control method with black start capability. This system can achieve ultimate safety under extreme undervoltage conditions through hardware-level self-power-off circuits, and can also achieve manual wake-up and communication reconstruction of the system in fault or islanded states through innovative black start logic, thereby improving the survivability and operational reliability of mobile energy storage devices under extreme conditions. Summary of the Invention
[0007] To address the aforementioned technical problems, this invention provides a mobile energy storage charging off-grid self-powered system with black-start capability and its control method. It improves safety under extreme undervoltage conditions through a hardware-level self-power-off circuit and enables manual wake-up and communication reconstruction of the system in fault or islanded states through black-start logic, thereby enhancing the survivability and operational reliability of mobile energy storage devices under extreme conditions. The mobile energy storage charging off-grid self-powered system with black-start capability includes: a self-power-off control board, a BMS main control board, a DC-DC converter, and a 4-pin start interface. The self-power-off control board is equipped with an optocoupler, a main control area, and an auxiliary power supply circuit. A button battery and a 4-pin start interface are installed in the main control area of the self-power-off control board. The button battery is connected to a manual button via the 4-pin start interface. The manual button is connected to the input of the optocoupler. The output of the optocoupler is connected to the 12V power supply of the DC-DC converter via a MOSFET in the auxiliary power supply circuit.
[0008] The self-power-off control board has a black start logic architecture and a self-power-off logic architecture.
[0009] The 12V power supply of the DC-DC converter is connected to the BMS motherboard. The self-power-off control board is responsible for physically cutting off power consumption and forced wake-up. The power source of the self-power-off control board is a button battery or a 12V auxiliary power source.
[0010] The BMS main control board is used to handle battery sampling, balancing, and communication logic. Its power source is the 12V output from the self-power-off control board.
[0011] The DC-DC converter steps down the high voltage of the battery pack into a low voltage auxiliary power source, while the power source is the high voltage battery pack.
[0012] The 4PIN startup interface serves as the entry point for external human-computer interaction and hardware wake-up.
[0013] Preferably, the self-power-off control board is equipped with a switch access interface, which has two channels, and each channel of the switch access interface is set independently.
[0014] Preferably, each of the switch access interfaces is defined as a power-on function interface.
[0015] Preferably, the black-start logic architecture is used for state awareness and interruption detection, fault shielding and emergency closure, and communication link reconstruction.
[0016] Preferably, the self-power-off logic architecture is used for multi-level SHUT threshold monitoring, physical disconnection and self-power-off actions, and power-off self-test.
[0017] A control method for a mobile energy storage charging off-grid self-powered system with black-start capability includes: Black-start processing flow:
[0018] Step 1: The system initializes and enters low-power standby mode;
[0019] Step 2: The power button is detected to be pressed continuously;
[0020] Step 3: Read the battery status. If there is a need for undervoltage shielding, load the "Black Start Strategy Table".
[0021] Step 4: Force the auxiliary power MOSFET to close, enabling the BMS to operate at full capacity;
[0022] Step 5: Initiate a synchronization handshake with the PCS (energy storage converter) and the DC-DC power supply module to attempt to establish an islanded voltage.
[0023] Preferably, the button is pressed for a duration of more than 3 seconds.
[0024] Compared with the prior art, the present invention has the following beneficial effects:
[0025] 1. This invention achieves system-level safe self-destruction and rapid emergency recovery under the premise of complying with the VDE-AR-E 2510-50 standard through a self-power-off control board architecture, a black-start logic architecture, and a self-power-off logic architecture. It solves the problems of safe self-destruction, low-power standby, and forced wake-up and system reconstruction of mobile energy storage systems under extreme undervoltage conditions and when external power and communication links are lost.
[0026] 2. This invention, through a hardware self-power-off circuit, reduces the self-power consumption of the mobile energy storage vehicle by over 98% during idle periods, effectively extending the static maintenance cycle of the battery pack. Compared to the traditional solution that requires recharging every quarter, this system can extend the maintenance interval to more than one year.
[0027] 3. The black start function of this invention eliminates the dependence on diesel generators, realizing true "zero emission" emergency rescue, and has irreplaceable advantages for power supply in enclosed spaces such as urban centers and basements.
[0028] 4. This invention complies with international export standards such as VDE-AR-E 2510-50, providing technical support for domestically produced mobile energy storage equipment to enter the global high-end market. Attached Figure Description
[0029] Figure 1 This is a block diagram of the self-power-off control board of a mobile energy storage charging off-grid self-powered system with black-start capability.
[0030] Figure 2 This is a block diagram of the black-start logic architecture.
[0031] Figure 3 This is a block diagram of the self-power-off logic architecture.
[0032] Figure 4 This is a flowchart of the black boot process.
[0033] Figure 5 These are diagrams illustrating the automatic power-off and hibernation actions under different fault levels.
[0034] Figure 6 These are the control targets for various key system indicators during the black boot process. Detailed Implementation
[0035] The present invention will be further described below with reference to the accompanying drawings:
[0036] In the picture:
[0037] As attached Figure 1 As shown,
[0038] A mobile energy storage charging off-grid self-powered system with black start capability includes a self-power-off control board, a BMS main control board, a DC-DC converter, and a 4-pin start interface. The self-power-off control board is equipped with an optocoupler and has a main control area and an auxiliary power supply circuit. A button battery and a 4-pin start interface are installed in the main control area of the self-power-off control board. The button battery is connected to a manual button through the 4-pin start interface. The manual button is connected to the input terminal of the optocoupler. The output terminal of the optocoupler is connected to the 12V power supply of the DC-DC converter through a MOSFET in the auxiliary power supply circuit.
[0039] The self-power-off control board has a black start logic architecture and a self-power-off logic architecture.
[0040] The 12V power supply of the DC-DC converter is connected to the BMS motherboard. The self-power-off control board is responsible for physically cutting off power consumption and forced wake-up. The power source of the self-power-off control board is a button battery or a 12V auxiliary power source.
[0041] The BMS main control board is used to handle battery sampling, balancing, and communication logic. Its power source is the 12V output from the self-power-off control board.
[0042] The DC-DC converter steps down the high voltage of the battery pack into a low voltage auxiliary power source, while the power source is the high voltage battery pack.
[0043] The 4PIN boot interface serves as the entry point for external human-computer interaction and hardware wake-up.
[0044] The introduction of optocouplers achieves electrical isolation between the control signal and the execution circuit, preventing high-voltage transients from impacting the human-machine interface buttons. When the operator presses and holds the black start manual button, the tiny current flowing through the circuit is sufficient to cause the gate charge of the MOSFET on the output side to accumulate to the turn-on threshold, thereby turning on the 12V power supply bus. This design achieves hardware wake-up in a "zero standby" state because no active device in the entire BMS system consumes battery power before the manual button is pressed.
[0045] When the manual button is pressed continuously, the input terminal of the optocoupler is turned on, and its output terminal triggers the MOSFET in the auxiliary power supply circuit of the self-power-off control board to turn on. This MOSFET acts as the main switch, controlling the 12V power supply from the high-voltage DC-DC converter to supply power to the BMS main control board.
[0046] In this implementation scheme, specifically, the circuit formed by the self-power-off control board, button battery, 4-pin start-up interface, optocoupler, and manual button does not rely on the high-voltage energy of the main battery cluster, ensuring that it still has activation capability in a completely dark state.
[0047] In this implementation plan, specifically, the self-disconnection control board is equipped with a switch access interface, which has two channels, and each channel of the switch access interface is set independently.
[0048] In this implementation scheme, each of the switch access interfaces is specifically defined as a power-on function interface to prevent startup failure caused by single-point physical damage.
[0049] In this implementation plan, in conjunction with the appendix Figure 2 As shown, the black start logic architecture is used for state awareness and interruption detection, fault shielding and emergency closure, and communication link reconstruction.
[0050] In this implementation scheme, specifically in the black-start logic architecture based on TIMER2 timer interrupt and BMM_Handle task flow:
[0051] Status awareness and interrupt detection: The black start button level is polled in real time within the TIMER2 interrupt service routine. The system can recognize long press commands and enter the black start preparation state;
[0052] Fault masking and emergency closure: Through the BMM_UpDateBStartInfo function, when the system detects a black start requirement, it conditionally masks the reporting of a single unit undervoltage level 3 fault and forcibly pulls up the internal control signal to drive the relay to close, thereby establishing an internal communication network with the liquid cooling unit and the charging module.
[0053] Communication link reconfiguration: In the event of an external communication failure (such as domain controller communication), the black start logic allows the secondary master controller to make independent decisions and close key contactors without relying on external commands, thereby enabling the system to self-power itself.
[0054] In this implementation plan, in conjunction with the appendix Figure 3 and attached Figure 5 As shown, the self-power-off logic architecture is used for multi-level SHUT threshold monitoring, physical disconnection and self-power-off action, and power-off self-test. When the battery is extremely low on power, the self-power-off logic architecture prioritizes sacrificing the availability of the control system in exchange for the physical safety of the battery cell.
[0055] In this implementation plan, specifically in the self-power-off logic architecture:
[0056] Multi-level SHUT threshold monitoring: When any of the individual unit voltage, module voltage, or system voltage is detected to be in a level 2 undervoltage state (e.g., individual unit ≤ 2.0V), and this state lasts for 6 minutes, the system determines that it has entered an "unrecoverable state".
[0057] Physical disconnection and self-power-off actions: For internal power supply systems, the MCU withdraws the latch signal, forcibly disconnecting the DC-DC power supply circuit, reducing the self-power consumption of the BMS system to zero. For external power supply systems, a deep sleep instruction is executed.
[0058] Power-off self-test: Within 10 seconds after the automatic power-off action is performed, the system will monitor the auxiliary power supply voltage. If the power-off fails, it will report "power-off circuit fault" to ensure that the system's safe state is controllable.
[0059] In this implementation plan, although the over-temperature fault is an unrecoverable state (requiring power-on to clear), it does not trigger the automatic power-off circuit. This is because maintaining the monitoring and heat dissipation control of the BMS under high temperature conditions is more critical for system safety, while the undervoltage automatic power-off is an extreme protection against power depletion.
[0060] In this implementation plan, specifically in the self-power-off logic architecture:
[0061] 1. Trigger threshold and time window
[0062] The system monitors the terminal voltage Vcell of each individual battery cell in real time. According to the VDE specification, when Vcell ≤ 2.0V, the chemical reaction inside the cell may lead to irreversible copper foil dissolution or dendrite growth. This invention sets a 6-minute decision window, Tshut.
[0063]
[0064] In this state, the system must store all operational data records (Black Box Data) before shutdown and ensure that the main positive and main negative contactors have been physically disconnected. Subsequently, the self-power-off control board MCU receives a "self-power-off command" from the main control board, disconnects the self-locking MOSFET, and cuts off all DC power supply.
[0065] 2. Fault diagnosis mechanism of self-disconnecting circuits
[0066] The automatic power-off action is not a simple power cut-off, but a closed-loop control process. After issuing the shutdown command, the system starts a 10-second monitoring timer;
[0067] Normal procedure: The voltage sampling point drops to 0V within 10 seconds, and the system is completely powered down.
[0068] Fault procedure: If the system still detects the power supply voltage after 10 seconds, it is determined to be a "shutdown circuit fault", which is usually caused by MOSFET breakdown or control logic lockout.
[0069] In this implementation plan, in conjunction with the appendix Figure 4 As shown, black start is a key function for mobile energy storage vehicles to achieve self-redemption in extreme environments (such as battery pack depletion, loss of external auxiliary power supply, and domain controller failure). A control method for a mobile energy storage charging off-grid self-powered system with black start capability includes: Black start processing flow:
[0070] S1: The system initializes and enters low-power standby mode;
[0071] S2: Power button continuously pressed detected;
[0072] S3: Read battery status. If there is a need for undervoltage shielding, load the "Black Start Strategy Table".
[0073] S4: Forces the auxiliary power MOSFET to close, enabling full BMS operation;
[0074] S5: Initiate a synchronization handshake with the PCS (energy storage converter) and the energy storage power module (DCDC) to attempt to establish an islanded voltage.
[0075] In this implementation scheme, specifically, the button is pressed continuously for more than 3 seconds.
[0076] In this implementation scheme, specifically, the black start implementation requires the cooperation of the TIMER2 interrupt service routine and BMM state machine management. The TIMER2 interrupt service routine polls the button status at a high frequency to ensure millisecond-level response speed; BMM state machine management: handles complex interlock checks in the background task flow to ensure that secondary disasters such as short circuits or thermal runaway are not caused during the black start process.
[0077] In this implementation plan, specifically, a black-start stability analysis is performed:
[0078] During black start, the mobile energy storage vehicle establishes a stable voltage source (grid-forming) in an off-grid state via the PCS. Since the load may include inductive loads such as motors, a huge inrush current is generated at the moment of startup.
[0079]
[0080] A "soft-start" strategy with a voltage ramp-up (see the formula above) is adopted. By adjusting the Tsoft parameter, the AC voltage is smoothly increased to the rated value within 200ms, avoiding a sudden drop in the terminal voltage of the undervoltage battery below the shutdown threshold due to a large current surge. Figure 6 These are the control targets for key system indicators during the black boot process.
[0081] Example 1: Forced power supply under a single-unit undervoltage level 3 fault:
[0082] When a single cell experiences a Level 3 undervoltage fault in the battery system, according to standard safety logic, the BMS will prevent the relay from closing. This results in the main control board having power but being unable to deliver energy externally. This could lead to system paralysis during emergency power supply tasks. The black-start solution for forced power supply under a Level 3 undervoltage fault is as follows:
[0083] Control logic: The operator manually presses the black start button (i.e., the power button);
[0084] Masking mechanism: After detecting this hardware signal, the BMS system temporarily masks the undervoltage protection flag through the BMM_UpDateBStartInfo function;
[0085] Communication establishment: The system closes the relay to guide electrical energy to the auxiliary power supply link and establishes communication with the liquid cooling unit and charging module. The purpose is to use the little remaining energy of the battery to try to restore the system through external power supply equipment or to perform emergency discharge to support the most critical load.
[0086] Example 2: Autonomous Operation Under Domain Controller Communication Failure:
[0087] In some cases, the battery system is normal, but the domain controller, acting as the host computer, is unable to send the command to close the relay to the secondary master controller due to electromagnetic interference or link interruption. In this situation, the mobile energy storage vehicle cannot work normally. The black-start solution for autonomous operation under domain controller communication failure is as follows:
[0088] Control logic: Pressing the black start button simulates an external heartbeat or resets the communication status.
[0089] Takeover mechanism: The secondary master controller identifies the status of the black start button, automatically switches to "off-grid autonomous management mode", and autonomously decides to close the relay to start the main control board and related components, which greatly enhances the field survivability of the system.
[0090] Any technical solution that achieves the above-mentioned technical effects by utilizing the technical solutions described in this invention, or by designing similar technical solutions by those skilled in the art under the inspiration of the technical solutions described in this invention, falls within the protection scope of this invention.
Claims
1. A mobile energy storage charging off-grid self-power system with black start capability, characterized in that, This mobile energy storage charging off-grid self-powered system with black start capability includes a self-power-off control board, a BMS main control board, a DC-DC converter, and a 4-pin start interface. The self-power-off control board is equipped with an optocoupler and has a main control area and an auxiliary power supply circuit. The main control area of the self-power-off control board is equipped with a button battery and a 4-pin start interface. The button battery is connected to a manual button through the 4-pin start interface. The manual button is connected to the input terminal of the optocoupler. The output terminal of the optocoupler is connected to the 12V power supply of the DC-DC converter through a MOSFET in the auxiliary power supply circuit. The self-power-off control board has a black start logic architecture and a self-power-off logic architecture. The 12V power supply of the DC-DC converter is connected to the BMS motherboard. The self-power-off control board is responsible for physically cutting off power consumption and forced wake-up. The power source of the self-power-off control board is a button battery or a 12V auxiliary power source. The BMS main control board is used to handle battery sampling, balancing, and communication logic. Its power source is the 12V output from the self-power-off control board. The DC-DC converter steps down the high voltage of the battery pack into a low voltage auxiliary power source, while the power source is the high voltage battery pack. The 4PIN startup interface serves as the entry point for external human-computer interaction and hardware wake-up.
2. The mobile energy storage charging off-grid self-powering system with black start capability of claim 1, wherein, The self-power-off control board is equipped with a switch access interface, which has two channels, and each channel is set independently.
3. The mobile energy storage charging off-grid self-powering system with black start capability of claim 1, wherein, Each of the aforementioned switch access interfaces is defined as a power-on function interface.
4. The mobile energy storage charging off-grid self-powering system with black start capability of claim 1, wherein, The black-start logic architecture is used for state awareness and interruption detection, fault shielding and emergency closure, and communication link reconstruction.
5. The mobile energy storage charging off-grid self-powering system with black start capability of claim 1, wherein, The self-power-off logic architecture is used for multi-level SHUT threshold monitoring, physical disconnection and self-power-off actions, and shutdown self-test.
6. A control method for a mobile energy storage charging off-grid self-powered system with black-start capability, characterized in that, include: Black boot process: Step 1: The system initializes and enters low-power standby mode; Step 2: The power button is detected to be pressed continuously; Step 3: Read the battery status. If there is a need for undervoltage shielding, load the "Black Start Strategy Table". Step 4: Force the auxiliary power MOSFET to close, enabling the BMS to operate at full capacity; Step 5: Initiate a synchronization handshake with the PCS (energy storage converter) and the DC-DC power supply module to attempt to establish an islanded voltage.
7. The control method for a mobile energy storage charging off-grid self-powered system with black-start capability as described in claim 6, characterized in that, The button is pressed for more than 3 seconds.