An intelligent charging system

Abstract

The application relates to an intelligent charging system in the field of charging. The system comprises a charging machine and a storage battery; the charging machine comprises a positive and negative pulse module connected with the storage battery, a control module, a temperature control module, a switching power supply module having one end connected with a power supply voltage and the other end connected with the control module and the positive and negative pulse module respectively; the control module is connected with the storage battery through the temperature control module; the temperature control module detects the real-time temperature of the storage battery, and when the real-time temperature of the storage battery is higher than a threshold temperature, a voltage increment value is calculated and fed back to the control module; the control module calculates an adjusted charging voltage based on the voltage increment value, and controls the switching power supply module to output the adjusted charging voltage to the storage battery; the positive and negative pulse module outputs positive and negative pulse voltages to the storage battery; the control module receives pulse signals of the positive and negative pulse module and carries out duty cycle modulation, and then outputs to the switching power supply module. The application is suitable for charging use in different seasons, avoids sulfuration failure of the storage battery, inhibits water loss of the storage battery, and improves the charging performance of the charging machine.

Description

Technical Field

[0001] This invention relates to the field of charging technology, and more particularly to an intelligent charging system. Background Technology

[0002] Currently, lead-acid battery chargers in China use various charging methods, including constant current, constant voltage, and float charging. These methods have several drawbacks: 1. In winter, the battery may not fully charge, leading to undercharging, which can cause sulfation, capacity loss, and ultimately, battery failure. 2. In summer, the battery is prone to bulging. To avoid undercharging in winter, the charger's constant voltage is often set to 14.7-14.9V (for a single 12V battery), or even higher. This significantly exceeds the battery's hydrogen and oxygen evolution voltages, causing irreversible water loss, especially in summer. Furthermore, water loss reduces the effective area of ​​the battery plates, increases the specific gravity of sulfuric acid, leading to plate corrosion and softening of the positive electrode active material. Ultimately, the battery is damaged by the charger.

[0003] Therefore, a charging system that can adapt to different seasonal temperatures is needed to control the charger to charge the battery properly, minimize battery water loss, and prevent thermal runaway that could lead to battery bulging and explosion.

[0004] Invention patent CN106451711B discloses a composite pulse lead-acid battery charger and its charging method, specifically disclosing the charging method, which includes the following steps: connecting the composite pulse lead-acid battery charger to a power source, converting AC power to DC power through a rectifier, and transmitting it to a power switching circuit; the power switching circuit receives a PWM pulse signal and controls the DC power signal output by the rectifier through the pulse signal, converting it into an AC power signal, and transmitting it as a voltage signal to a transformer; the transformer changes the voltage output by the power switching circuit and converts the voltage signal into a digital signal through an analog-to-digital converter, transmitting it to a microcontroller; detecting the temperature change of the charger during charging, converting the detection signal into a digital signal through an analog-to-digital converter, and transmitting it to the microcontroller; the microcontroller processes the temperature change signal detected by the temperature detection circuit and the voltage signal transmitted by the transformer, converting it into a composite pulse signal, and transmitting the composite pulse signal to an optocoupler; the optocoupler receives the composite pulse signal from the microcontroller and transmits it... The signal is processed and converted into a pulse signal that can be received by PWM; PWM receives the pulse signal transmitted by the optocoupler and transmits it to the power switch circuit to control the opening and closing of the switch in the power switch circuit, thereby regulating the duty cycle of the positive and negative pulses; the generation process of the composite pulse signal is as follows: (1) Slow pulse with high frequency pulse charging inside This stage is the charging process, including multiple sawtooth waveform charging, each sawtooth waveform is a cycle, the frequency of the cycle is 180-210Hz, and each large sawtooth waveform is embedded with a small sawtooth waveform with a frequency of 50-65KHz. The entire slow pulse with high frequency pulse charging stage lasts for 3-4 hours; (2) Composite positive and negative pulse charging process includes the charging process before and after the composite positive and negative pulse charging, and the entire composite positive and negative pulse charging process lasts for 1-2 hours; the charging process before and after both stages includes: positive pulse charging, zero pulse stopping and negative pulse discharging; slow pulses are embedded inside both positive and negative pulses, the positive pulse frequency is 180-210Hz, and the slow pulse frequency is 55-60KHz. This invention uses a composite pulse signal synthesized from temperature and voltage signals to control a power switching circuit, thereby regulating the duty cycle of the positive and negative pulses, primarily improving the pulse charging mode. However, the invention does not specify how the composite pulse signal is synthesized from the temperature and voltage signals; it only states that the composite pulse signal includes a slow pulse containing a high-frequency pulse charging stage, a pre-charging stage of the composite positive and negative pulse charging process, and a post-charging stage. It fails to address how temperature affects battery charging. Summary of the Invention

[0005] This invention addresses the problems existing in the prior art by proposing an intelligent charging system that can adapt to charging in different seasons, avoid battery sulfation failure, improve charger performance, and extend battery life.

[0006] This invention is achieved through the following technical solution:

[0007] An intelligent charging system includes a charger and a battery. The charger includes a switching power supply module, a positive and negative pulse module, a control module, and a temperature control module. One end of the switching power supply module is connected to a power supply voltage, and the other end is connected to the control module and the positive and negative pulse module. The positive and negative pulse module is also connected to the battery. The control module is connected to the battery via the temperature control module. The temperature control module is used to detect the real-time temperature of the battery, and when the detected real-time temperature of the battery is higher than a threshold temperature, it calculates a voltage increment and feeds it back to the control module. The control module calculates an adjusted charging voltage based on the voltage increment and controls the switching power supply module to output the adjusted charging voltage to the battery. The positive and negative pulse module is used to output positive and negative pulse voltages to the battery. The control module receives the pulse signals from the positive and negative pulse module, modulates their duty cycle, and then outputs them to the switching power supply module.

[0008] This invention accurately measures the actual temperature of the battery and calculates the potential at which a large amount of gas is evolved, ensuring that the charging voltage is always controlled below the potential for significant hydrogen and oxygen evolution, thus reducing water loss and extending battery life. Furthermore, the charger employs adjustable duty cycle pulse charging with depolarization pulses, thereby reducing the battery temperature during charging.

[0009] Preferably, the temperature control module includes:

[0010] Temperature detection unit is used to detect the real-time temperature of the battery;

[0011] The voltage increment calculation unit is used to determine the voltage increment value △U according to the voltage increment formula △U=n*△Ubase(T -Tt); where n is the number of individual cells in the battery pack connected in series; △Ubase is the voltage value that needs to be reduced for every 1℃ increase; T is the real-time temperature of the battery detected by the temperature detection unit, and Tt is the threshold temperature.

[0012] Preferably, the control module includes:

[0013] The battery gas evolution voltage calculation unit is used to determine the battery gas evolution voltage U according to the battery gas evolution voltage formula U=n*Umax+△U; where Umax is the maximum float charge voltage when both oxygen and hydrogen are evolved; △U is the voltage increment value.

[0014] The charging voltage control unit is used to control the output charging voltage, which is lower than the battery gas evolution voltage, to be supplied to the battery via the switching power supply module;

[0015] The duty cycle modulation unit is used to perform duty cycle modulation based on the pulse signal sent by the positive and negative pulse modules and output it to the switching power supply module.

[0016] Preferably, the control module further includes an overcharge control unit, which periodically controls the charging voltage to rise to an overcharge voltage and outputs the overcharge voltage to the battery.

[0017] Preferably, the control module further includes a cycle setting unit for setting the overcharge control unit startup cycle.

[0018] Preferably, the overcharge control unit start-up cycle is determined based on the number of times the charger is used or the charger's usage capacity.

[0019] Preferably, the overcharge voltage is equal to (1+10%)*charging voltage.

[0020] Preferably, the control module further includes a repair unit for controlling the oscillation frequency of the positive and negative pulse voltage outputs.

[0021] Preferably, the switching power supply module includes a multi-channel switching circuit.

[0022] Preferably, the charger also includes a display screen for displaying the charger's charging voltage, charging current, and usage capacity.

[0023] The present invention has the following beneficial effects:

[0024] An intelligent charging system can achieve depolarization using adjustable duty cycle pulse charging; it can calculate the battery gas evolution voltage based on the battery temperature and control the charging voltage below the battery gas evolution voltage to avoid generating a large amount of gas evolution, thereby reducing water loss; and it can eliminate battery polarization during charging by using positive and negative pulse charging modes to reduce battery temperature rise. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of a smart charging system according to the present invention;

[0026] Figure 2 for Figure 1 Electrical schematic diagram of the internal components of the charger;

[0027] Figure 3a , Figure 3b They are respectively Figure 1 Circuit diagrams of the charging circuit and the discharging circuit of the positive and negative pulse module.

[0028] Figure 4 for Figure 1 Logic diagram of positive and negative pulse control time. Detailed Implementation

[0029] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0030] like Figure 1 A smart charging system includes a charger and a battery. The charger includes a switching power supply module, a positive and negative pulse module, a control module, and a temperature control module. One end of the switching power supply module is connected to a power supply voltage, and the other end is connected to both the control module and the positive and negative pulse module. The positive and negative pulse module is also connected to the battery. The control module is connected to the battery via the temperature control module. The temperature control module detects the real-time temperature of the battery, and when the detected real-time battery temperature is higher than a threshold temperature, calculates a voltage increment and feeds it back to the control module. The control module outputs an adjusted charging voltage to the battery based on the voltage increment. The positive and negative pulse module outputs positive and negative pulse voltages to the battery. The control module receives the pulse signals from the positive and negative pulse module, modulates their duty cycle, and then outputs the voltages to the switching power supply module.

[0031] The power supply voltage is three-phase. The switching power supply module is an AC / DC switching power supply used to power the control module and the positive and negative pulse modules. When the control module receives a pulse signal and modulates its duty cycle, the switching power supply module outputs a modulated power signal to the positive and negative pulse modules to control them to output depolarization pulses to the battery. The switching power supply module can be a commercially available module, which can be equipped with multiple switches.

[0032] The positive and negative pulse module is used to output positive and negative pulse voltages to the battery, suppressing and eliminating battery sulfation through the leading and trailing edges of the positive and negative charging pulses. Charging by the positive and negative pulse module is implemented by two hardware circuits: charging and discharging (see...). Figure 3a , Figure 3b ), Figure 2 The diagram shows the electrical schematic of the positive and negative pulse module implemented inside the charger. Both positive pulse charging and negative pulse charging are achieved by PWM control output from the control module. Figure 3a For charging circuit, Figure 3b In the discharge circuit, during charging, MOSFETs M5, M1, and M2 in the charging circuit are turned on, and the charging circuit is active. MOSFETs M6, M7, and M3 in the discharge circuit are turned off, and the discharge circuit is disconnected, allowing the switching power supply module to charge the battery. After the charging time has elapsed, during discharging, MOSFETs M6, M7, and M3 in the discharge circuit are turned on, and the discharge circuit is active. MOSFETs M5, M1, and M2 in the charging circuit are turned off, and the charging circuit is disconnected. The battery discharges through the discharge resistor for a duration of t_discharge. The specific timing control of the charging and discharging circuits is as follows: Figure 4 As shown.

[0033] During battery charging, three major polarizations occur (concentration polarization, Ohm's law polarization, and electrochemical polarization), thus generating heat. The positive and negative pulse module, modulated by the control module, outputs positive and negative pulse voltages to the battery. The negative pulse helps to improve battery polarization, thereby reducing the battery temperature during charging.

[0034] The temperature control module includes a temperature detection unit and a voltage increment calculation unit. The temperature detection unit detects the real-time temperature of the battery. This unit can be implemented using a temperature detection circuit, which sends the collected temperature data to the voltage increment calculation unit. The voltage increment calculation unit determines the voltage increment value ΔU according to the voltage increment formula ΔU=n*ΔUbase(T -Tt); where n is the number of individual cells in the battery pack connected in series; ΔUbase is the voltage reduction required for every 1°C increase; T is the real-time battery temperature detected by the temperature detection unit; and Tt is the threshold temperature. Generally, ΔUbase is set to 3-5mV, and Tt is set to 25 degrees Celsius.

[0035] The control module includes a battery gas evolution voltage calculation unit, a charging voltage control unit, and a duty cycle modulation unit. The battery gas evolution voltage calculation unit determines the battery gas evolution voltage U according to the formula U=n*Umax+ΔU, where Umax is the maximum float charge voltage when both oxygen and hydrogen are evolved, and ΔU is the voltage increment. The charging voltage control unit controls the output charging voltage to the battery to be lower than the battery gas evolution voltage. This invention utilizes voltage increments per unit time to control and reduce the charging voltage, thereby avoiding excessive gas evolution and reducing water loss. The duty cycle modulation unit modulates the duty cycle based on the pulse signals sent by the positive and negative pulse modules and outputs the modulated value to the switching power supply module. The control module preferably uses an STM32f72CBT6 chip and its peripheral circuitry, which are connected to the positive and negative pulse module, the temperature control module, and the switching power supply module, respectively.

[0036] Because the battery operates at a low potential for extended periods, its capacity may decrease. Therefore, a periodic overcharge cycle is necessary to improve battery performance and prevent sulfation. The control module includes an overcharge control unit, which periodically controls the charging voltage to rise to an overcharge voltage and outputs this overcharge voltage to the battery. The control module also includes a cycle setting unit for setting the overcharge control unit's activation cycle. This cycle is determined based on the charger's usage frequency or capacity. For example, an overcharge mode might be activated approximately every 15-25 uses. This can be done automatically or manually as needed. The overcharge voltage can be set as required, for example, as (1 + 10%) * charging voltage. This voltage is determined based on the charger's daily usage, such as using the most recent charging voltage or the average charging voltage over a recent period.

[0037] The control module also includes a repair unit for controlling the oscillation frequency of the positive and negative pulse voltage outputs.

[0038] This repair function utilizes the principle of resonance to break up lead sulfate crystals by oscillating at the same frequency as the lead sulfate crystals, thus repairing the battery. The repair unit outputs a PWM control to switch the charging circuit MOSFET on and off according to a preset oscillation frequency. At this frequency, crystallization can be effectively eliminated, extending battery life. This repair function is generally used when the battery is severely degraded and needs to be manually activated on the display screen. For example, in low current (10% of rated current) mode, at a frequency of 8.333kHz (consistent with the lead sulfate crystal oscillation frequency), the charging circuit MOSFET is controlled to switch on and off. In this mode, the current frequency resonates with the lead sulfate crystals, breaking them up.

[0039] The charger also includes a display screen for displaying the charger's charging voltage, charging current, and usage capacity.

[0040] Those skilled in the art should understand that the embodiments of the present invention described above and shown in the accompanying drawings are merely examples and do not limit the present invention. The objectives of the present invention have been fully and effectively achieved. The functions and structural principles of the present invention have been shown and explained in the embodiments, and any modifications or variations of the implementation of the present invention may be made without departing from the stated principles.

Claims

1. An intelligent charging system, comprising a charger and a battery; characterized in that... The charger includes a switching power supply module, a positive and negative pulse module, a control module, and a temperature control module. One end of the switching power supply module is connected to the power supply voltage, and the other end is connected to the control module and the positive and negative pulse module respectively. The positive and negative pulse module is also connected to the battery. The control module is connected to the battery via the temperature control module. The temperature control module is used to detect the real-time temperature of the battery, and when the detected real-time temperature of the battery is higher than a threshold temperature, it calculates the voltage increment value and feeds it back to the control module. The control module calculates the adjusted charging voltage based on the voltage increment value and controls the switching power supply module to output the adjusted charging voltage to the battery. The positive and negative pulse module is used to output positive and negative pulse voltages to the battery. The control module receives the pulse signals from the positive and negative pulse module and modulates the duty cycle, and then outputs them to the switching power supply module. The temperature control module includes: Temperature detection unit is used to detect the real-time temperature of the battery; The voltage increment calculation unit is used to calculate the voltage increment based on the formula ΔU=n*ΔU. base (TT) t Determine the voltage increment value ΔU; where n is the number of individual cells in the battery pack connected in series; ΔU base T represents the voltage reduction required for every 1°C increase in temperature; T is the real-time battery temperature detected by the temperature detection unit. t Threshold temperature; The control module includes: The battery gas evolution voltage calculation unit is used to calculate the battery gas evolution voltage based on the formula U=n*U. max +△U determines the battery gas evolution voltage U; where U max ΔU represents the maximum float charge voltage when both oxygen and hydrogen are released; ΔU is the voltage increment value. The charging voltage control unit is used to control the output charging voltage, which is lower than the battery gas evolution voltage, to be supplied to the battery via the switching power supply module; The duty cycle modulation unit is used to perform duty cycle modulation based on the pulse signal sent by the positive and negative pulse modules and output it to the switching power supply module. An overcharge control unit is used to periodically control the charging voltage to rise to an overcharge voltage and output the overcharge voltage to the battery. The overcharge voltage is equal to (1+10%)*charging voltage.

2. The intelligent charging system according to claim 1, characterized in that, The control module also includes a cycle setting unit for setting the overcharge control unit startup cycle.

3. The intelligent charging system according to claim 2, characterized in that, The overcharge control unit's activation cycle is determined based on the number of times the charger is used or the charger's capacity.

4. The intelligent charging system according to claim 1, characterized in that, The control module also includes a repair unit for controlling the oscillation frequency of the positive and negative pulse voltage outputs.

5. The intelligent charging system according to claim 1, characterized in that, The switching power supply module includes a multi-channel switching circuit.

6. The intelligent charging system according to claim 1, characterized in that, The charger also includes a display screen for displaying the charger's charging voltage, charging current, and usage capacity.

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