Battery heating management system and battery heating control method for overhead line traveling robot

Abstract

The application provides an overhead line walking robot battery heating management system and a control method, which can solve the problem that the battery cannot be charged in a low-temperature state of the overhead line walking robot, and forced charging may even damage the battery core. The battery heating management system comprises a battery compartment provided on the robot and used for storing the battery; a heating film provided in the battery compartment and used for heating the battery; a temperature sensor used for collecting the surface temperature of the battery; a main control board used for communication control of the battery; a wireless communication module used for wireless communication connection between the charging device and the overhead line walking robot; and a positioning system and the main control board.

Description

Technical Field

[0001] This invention relates to a battery heating management system and battery heating control method for an overhead line walking robot. Background Technology

[0002] To address icing issues and other problems on high-voltage, ultra-high-voltage, and extra-high-voltage transmission lines, the development of transmission line walking robots for inspection and de-icing operations is imperative. However, current use of these robots presents several challenges: Firstly, the operating environment for overhead line walking robots is typically high-altitude, where temperatures are low. Batteries using ordinary low-temperature cells cannot be charged below 0°C, while those using special low-temperature cells are bulky, heavy, and expensive. Secondly, at temperatures below 0°C, the batteries require heating. Charging is often initiated before all internal cells reach above 0°C, leading to cell damage and reduced battery capacity and lifespan. Thirdly, current overhead line walking robots lack a comprehensive battery warning model that integrates factors such as return distance, return time, current battery level, current temperature, and current voltage. This increases the risk of the robot becoming stranded on the overhead line due to depleted battery power. Furthermore, current overhead line walking robots... Currently, the preheating process for overhead power line robots doesn't accurately predict when to heat up, potentially leading to premature heating, energy waste, or the robot being unable to return. Furthermore, the preheating power settings don't accurately reflect the actual heating conditions, potentially causing excessive power heating, energy waste, or the robot being unable to return. Additionally, when any battery cell temperature is below 0°C, the current BMS doesn't actively shut off the charging MOSFETs, increasing the risk of direct low-temperature charging and cell damage. Moreover, the current system only heats the battery after reaching the charging point, increasing charging time and reducing overall inspection efficiency. It also fails to utilize remaining battery power during return, reducing battery efficiency. Finally, during charging, the charging equipment simultaneously charges the battery and supplies power to the load after the connection is established, which can damage the battery below 0°C. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention provides a battery heating management system for an overhead line walking robot. This system uses battery heating to manage the battery temperature, keeping the battery cells within a reasonable charging temperature range. This protects the battery, reduces the robot's overall size, weight, and cost, and solves the current problem that batteries in overhead line walking robots cannot be charged in low-temperature conditions, and that forced charging may even damage the battery cells.

[0004] Another objective of this invention is to provide a battery heating control method. This method, after the robot returns to base and is charged, does not charge the battery immediately, but heats it first. Once the internal cell temperature of the battery reaches a reasonable charging range, the battery is then charged. This effectively protects the battery and extends its lifespan. It can solve the problem that when overhead line walking robots return to base and charge in low-temperature conditions, the stored power is insufficient to achieve the desired heating effect, and forced heating may even lead to the risk of over-discharging the battery.

[0005] The present invention adopts the following technical solution:

[0006] A battery heating management system for an overhead line walking robot, wherein the overhead line walking robot moves along overhead lines erected by poles via a walking mechanism to inspect and / or perform operations on the overhead lines, the overhead line walking robot is charged by a charging device located at a fixed charging position on the pole, and the overhead line walking robot is equipped with a battery for storing and releasing electricity, the battery heating management system comprising:

[0007] A battery compartment for storing batteries is provided on the overhead line walking robot;

[0008] A heating film for heating the battery is provided inside the battery compartment;

[0009] Temperature sensor used to collect battery surface temperature;

[0010] A main control board for communication control of the battery is located on the overhead line walking robot. The main control board is electrically connected to the temperature sensor. The main control board controls the heating film to heat up or stop heating according to the signal from the temperature sensor.

[0011] A wireless communication module is used to enable wireless communication between the charging device and the overhead line walking robot. The main control board on the overhead line walking robot obtains information from the charging device through the wireless communication module.

[0012] as well as,

[0013] A positioning system is used to confirm the current position of the overhead line walking robot, and calculates the return mileage based on the confirmed current position information of the overhead line walking robot; the overhead line walking robot obtains information about the charging equipment through the main control board, the main control board and the main control board are signal connected, and the main control board controls the overhead line walking robot to return to the charging position according to the data of the main control board.

[0014] Preferably, it also includes a host computer, which is communicatively connected to the overhead line walking robot and is used to issue task instructions to the overhead line walking robot.

[0015] Preferably, the heating film is configured as a silicone rubber heating film.

[0016] Preferably, the heating film is configured to be arranged close to the left, right, and bottom sides of the battery, the heating film is configured to have a size corresponding to the left, right, and bottom sides of the battery, and the temperature sensor is configured to be placed close to the upper surface of the battery.

[0017] Preferably, it also includes a switch driver board for controlling the switching of the heating film. The switch driver board is a PWM-controlled switch driver board. The main control board is electrically connected to the switch driver board. The main control board controls the switch driver board to turn the silicone heating film on or off according to the signal from the temperature sensor.

[0018] Preferably, the main control board communicates with the battery management system (BMS).

[0019] Preferably, the battery compartment also includes insulating cotton for keeping the battery warm, the insulating cotton being arranged to be tightly attached to the inner surface of the battery compartment.

[0020] Preferably, the wireless communication module includes a wireless module located in the charging device and a wireless module located on the main control board of the overhead line walking robot, and the two communicate via Bluetooth or 433M wireless.

[0021] Preferably, the overhead line walking robot is provided with a robot-side charging port electrically connected to the battery for charging the battery. The battery has a charging port and a discharging port. The overhead line walking robot-side charging port is connected to the charging port of the battery, and the charging device-side charging port is connected to the charging device output port.

[0022] Preferably, it also includes a charging limit switch for confirming whether the robot has reached the charging position.

[0023] The present invention also relates to a battery heating control method applied to the battery heating management system described above, including step 1: when the temperature sensor value T1 is lower than 0°C, the main control board communicates with the battery, reads the battery BMS information, parses the temperature of each cell sampled by the battery BMS, and compares and obtains the lowest cell temperature T2 and the current battery voltage U1.

[0024] Step 2: Determine whether T1 is less than T2 when T2 is below 0℃. If not, continue to step 3; if yes, proceed to step 4.

[0025] Step 3: Calculate the temperature difference ΔT between the current battery temperature and the normal charging temperature of the battery to ensure that the minimum cell temperature is 5℃ during charging, i.e., heating temperature difference ΔT = -T2 +5;

[0026] Step 4: Calculate the temperature difference ΔT between the current battery temperature and the normal charging temperature of the battery to ensure that the minimum cell temperature is 5℃ during charging, i.e., heating temperature difference ΔT = -T1 +5.

[0027] Preferably, the battery heating control method includes:

[0028] Step 1: Read the temperature sensor value T1, then proceed to Step 2;

[0029] Step 2: Determine if T1 is below 0℃. If not, proceed to Step 1; if yes, proceed to Step 3.

[0030] Step 3: The main control board communicates with the battery, reads the battery BMS information, analyzes the temperature of each cell sampled by the battery BMS, compares and obtains the lowest cell temperature T2 and the current battery voltage U1, and continues to execute step 4.

[0031] Step 4: Determine if T2 is below 0℃. If not, continue to Step 3; if yes, proceed to Step 5.

[0032] Step 5: Determine if T1 is less than T2. ​​If not, proceed to Step 6; if yes, proceed to Step 7.

[0033] Step 6: Calculate the temperature difference ΔT between the current battery temperature (i.e., the smaller value of T1 and T2) and the normal charging temperature of the battery, and ensure that the minimum cell temperature is 5℃ during charging, i.e., heating temperature difference ΔT = -T2 +5, and continue to step 8;

[0034] Step 7: Calculate the temperature difference ΔT between the current battery temperature and the normal charging temperature of the battery, and ensure that the minimum temperature of the battery cell is 5℃ during charging, that is, the heating temperature difference ΔT = -T1 +5, and continue to step 8.

[0035] Step 8: Calculate the energy required to heat the current battery from its current temperature to its charging temperature. The total heating energy is W1 = cmΔT / α, where c is the specific heat capacity of the battery cell material, m is the total mass of the battery, and α is the battery compartment insulation coefficient. Continue to step 9.

[0036] Step 9: There are 3 heating films on the left, bottom and right sides of the battery. Define the rated heating power of a single heating film as P3. Calculate the heating time t3 required to heat the heating film under the rated power. t3 = W1 / P3 / 3. Continue to step 10.

[0037] Step 10: Disconnect the battery charging circuit to prevent the charging equipment from charging the battery cells in sub-zero conditions; continue to step 11;

[0038] Step 11: Read the positioning information, analyze the robot's current location, calculate the distance S between the robot and the charging location, and continue to step 12;

[0039] Step 12: Read the robot's running speed v, calculate the return motion time t1=S / v; set the robot's average motion power value to P1; continue to step 13;

[0040] Step 13: Based on the currently analyzed position of the robot, calculate the number of towers that need to be crossed, which is n; set the time for the robot to cross a single tower to be t2; set the average power of the robot crossing a single tower to be P2; continue to step 14;

[0041] Step 14: Calculate the total time t for the robot to return at this moment, t = t1 + n * t2; continue to step 15;

[0042] Step 15: Calculate the total power consumption W2 of the robot returning to home at this moment, W2=P1*t1+P2*n*t2; continue to execute step 16;

[0043] Step 16: Calculate the power Q1 required for the robot to return to home at this moment, Q1 = W2 / U1; continue to step 17;

[0044] Step 17: The main control board communicates with the battery, reads the battery BMS information, reads the current battery level Q2, and continues to execute step 18;

[0045] Step 18: Calculate the current remaining battery power Q3 of the robot, Q3 = Q2 - Q1, and continue to step 19;

[0046] Step 19: Calculate the current surplus energy W3 of the robot's battery, W3 = Q3 * U1, and continue to step 20;

[0047] Step 20: Determine whether the robot is moving in the direction of returning to the charging position or moving away from the charging position. If the robot is moving in the direction of returning to the charging position, proceed to step 26; if the robot is moving in the direction of moving away from the charging position, proceed to step 21.

[0048] Step 21: Determine if Q3 is less than 15%. If not, proceed to step 22; if yes, proceed to step 23.

[0049] Step 22: Continue to execute the current task, namely the inspection and / or de-icing task issued by the host computer (i.e., the remote computer);

[0050] Step 23: The main control board reports the current battery temperature, cell temperature, battery level, return range, and remaining power to the host computer, issues a battery level warning to the host computer, and continues to execute step 24;

[0051] Step 24: Wait for the host computer to issue a return command. If yes, continue to step 25; otherwise, continue to step 23.

[0052] Step 25: Upon receiving the return command from the host computer, turn the robot's forward direction and continue to execute Step 26;

[0053] Step 26: Determine if the battery's remaining charge is greater than 5%; if yes, proceed to step 27; if no, proceed to step 31.

[0054] Step 27: Determine whether the total return time t is less than the battery heating time t3; if yes, proceed to step 28; if no, proceed to step 26.

[0055] Step 28: Determine whether the current surplus energy W3 of the robot battery is less than the total energy W1 required for battery heating; if yes, proceed to step 29; if no, proceed to step 30.

[0056] Step 29: Calculate the PWM output duty cycle D of the main control board, D=W3 / W1, and continue to step 32;

[0057] Step 30: If the PWM output duty cycle D of the main control board is 100%, continue to execute step 32;

[0058] Step 31: If the PWM output duty cycle D of the main control board is 0%, continue to step 35;

[0059] Step 32: The power supply voltage of the driver board responsible for amplifying the driving capability is 24V, and the output voltage of the driver board is U2, U2=24*D. Continue to execute step 33.

[0060] Step 33: The heating power P4 of a single heating film is proportional to the input voltage, P4=D*P3, continue to step 34;

[0061] Step 34: Turn on the battery heater to preheat the battery, then continue to step 36;

[0062] Step 35: Stop battery heating and proceed to step 36;

[0063] Step 36: Determine whether the robot charging position limit switch is closed. This limit switch is triggered to close when the robot reaches the charging position. If not, continue to step 26; if yes, proceed to step 37.

[0064] Step 37: The main control board communicates with the charging device through the wireless communication module, reads and parses the charging device information, and continues to execute step 38;

[0065] Step 38: Determine whether there is charging current output at the output terminal of the charging device. If not, continue to step 37; if yes, proceed to step 39.

[0066] Step 39: The main control board adjusts the output duty cycle D=100%, the heating film is at rated power output, the battery heating is turned on, and then proceed to step 40;

[0067] Step 40: Disconnect the battery discharge circuit and use only the charging device to power the overhead line walking robot, then continue to step 41;

[0068] Step 41: Determine if the temperature of all battery cells is greater than 5°C. If not, continue to step 41; if yes, proceed to step 42.

[0069] Step 42: Determine whether the temperature of the battery surface temperature sensor is greater than 5°C. If not, continue to step 42; if yes, proceed to step 43.

[0070] Step 43: Charge the battery and monitor and upload the battery level in real time.

[0071] Preferably, in step 1, T1 is read cyclically once every 1 minute;

[0072] In step 11, the location information is read cyclically every 30 seconds;

[0073] In step 12, the robot's running speed v is read cyclically every 30 seconds.

[0074] Compared with the prior art, the technical solution provided by this invention has the following advantages:

[0075] 1. When a temperature below 0°C is detected on the battery surface or in any battery cell, the system communicates with the battery and cuts off the charging circuit to the battery cell. This protects the battery cell in low-temperature conditions and prevents the charging device from directly charging the battery when it is below 0°C after the robot returns to the charging point and the physical charging port is established, which could damage the battery cell. This reduces the risk of direct low-temperature charging and extends the battery's lifespan.

[0076] 2. During the inspection operation on the line, the robot can detect its current position in real time through the positioning system, calculate the return distance and the power required for the return, and ensure that the robot's battery power is sufficient to meet the robot's return needs. This greatly reduces the risk of the robot being unable to return safely due to battery power issues, thus causing it to be stranded on the overhead line.

[0077] 3. When the remaining battery power is below the threshold and the robot's movement direction is away from the charging position on the pole, a battery power warning is sent to the host computer. This can assist the host computer in making reasonable task allocation and ensure that the specified task can be completed under the premise of safe return.

[0078] 4. When the robot turns on the heating, it can calculate and adjust the battery heating power in real time based on the quantitative relationship between the current battery power and the energy required for battery heating. This can prevent the battery from using too much energy for heating, which could affect the robot's safe return. It can also make full use of the remaining battery energy and improve battery heating efficiency.

[0079] 5. Based on the current battery temperature, calculate the energy required for battery heating. Under the condition of a certain heating power, calculate in real time when to start heating when the robot returns. This can maximize the use of the battery's own energy, avoid wasting energy due to premature heating, and prevent the battery energy from being depleted due to premature heating. It can also start battery heating in advance while ensuring the robot's safe return, thereby improving battery charging efficiency and thus improving the robot's inspection efficiency.

[0080] 6. When the robot's return mileage, calculated from its real-time position, is less than a set threshold, determine if the current battery capacity meets the threshold for activating battery heating. If it does, activate battery heating; otherwise, continuously check this logic. Battery heating may be activated when the return mileage is half the set threshold. This allows for early activation of heating during the robot's return journey, provided the battery capacity is sufficient. It maximizes battery energy utilization and improves battery energy efficiency. Early activation of heating reduces the time the robot spends heating the battery at the charging station, improving charging efficiency, reducing overall robot inspection time, and increasing robot utilization.

[0081] 7. When the robot reaches the charging limit point and detects that there is charging current in the charging device, it controls the battery to shut down and discharge. The heating film is powered directly by the external charging device to heat the battery. During the heating process, the current battery charge can be maintained, reducing the charging time after the battery cools down and increasing the overall utilization rate of the robot. At the same time, it reduces the risk of the battery running out of power or even over-discharging during the heating process and extends the battery's lifespan.

[0082] 8. The battery surface temperature and the temperature of all battery cells must be above 5°C before the battery charging MOSFET and discharging MOSFET can be turned on to charge the battery. This invention prevents the relay from frequently turning on and off by judging the condition by turning the MOSFET off and on by 5°C, thereby reducing the relay failure rate and extending the service life of the relay. Attached Figure Description

[0083] Figure 1This is a hardware structure connection diagram of the robot battery heating system provided in an embodiment of the present invention.

[0084] Figure 2 The flowchart of the robot battery heating system provided in this embodiment of the invention is shown.

[0085] Figure 3-6 for Figure 2 A magnified view of a portion of the image. Detailed Implementation

[0086] To further understand the content of this invention, a detailed description of the invention will be provided in conjunction with the accompanying drawings and embodiments.

[0087] The battery heating management system for the overhead line walking robot in this embodiment is commonly used in applications involving overhead line inspection robots. The robot uses a walking mechanism to inspect and / or perform operations on overhead lines supported by multiple poles. The robot is charged via charging devices located at fixed charging positions on the poles. The robot is equipped with a battery for storing and releasing battery power. The battery heating management system mainly includes a battery heating section and an auxiliary control section, specifically including:

[0088] A battery compartment is provided on the robot for storing batteries;

[0089] A heating film for heating the battery is provided inside the battery compartment;

[0090] Temperature sensor used to collect battery surface temperature;

[0091] A main control board is used for communication control of the battery. The main control board is electrically connected to the temperature sensor. The main control board controls the silicone heating film to heat up or stop heating based on the signal from the temperature sensor.

[0092] A wireless communication module is used to enable wireless communication between the charging device and the robot, and the main control board on the robot obtains information about the charging device through the wireless communication module.

[0093] as well as,

[0094] The positioning system used to confirm the robot's current location calculates the return mileage based on the confirmed current location information of the robot.

[0095] Located on the main control board of the robot, the robot obtains information about the charging device through the main control board. The main control board and the main control board are signal connected. The main control board controls the robot to return to the charging position according to the data of the main control board.

[0096] The actual application scenario of this line inspection robot is on the ground wire of power transmission lines. Combined with visible light infrared, drive motor, robotic arm and other peripherals, it can carry out inspection and operation of power transmission lines and towers. It can reduce the danger, tediousness and false detection rate of manual inspection. The battery heating management system of this overhead line walking robot can ensure that ordinary batteries can be quickly charged below 0℃ and maximize the battery discharge utilization rate, ensuring that the robot can return safely. The application scenario mainly consists of robot body end, tower charging station, near-end back-end, and remote server.

[0097] 1. Robot body end

[0098] (1) The robot body is attached to the ground wire of the power transmission line. Its main function is to move on the ground wire through the drive wheel, thereby realizing functions such as inspection, de-icing and operation.

[0099] (2) Communication of the robot body: It communicates with the near-end back-end and the charging stations on each pole through 2.4G / 5.8G wifi; and communicates with the customer's remote server through 4G / 5G public network.

[0100] (3) Power supply for the robot body: The robot is powered by lithium batteries and is charged after interacting with the charging station system;

[0101] 2. Pole charging station

[0102] (1) The charging station is fixedly installed on the pole and its main function is to charge the robot body by contact.

[0103] (2) The charging station is powered by solar panels, and the lead-acid batteries store energy. The lead-acid batteries supply energy to the charger through an inverter.

[0104] (3) The charging station communicates with the near-end backend and the robot body via 2.4G / 5.8G Wi-Fi;

[0105] 3. Near-end backend

[0106] (1) The near-end back-end is located within 50-100m of the bottom of the tower. Its main functions are on-site debugging, collection of robot body data, and on-site emergency control.

[0107] (2) The near-end back-end can be powered by mains power or mobile power supply; (3) The near-end back-end communicates with the robot body and the charging stations on each pole via 2.4G / 5.8G WiFi;

[0108] 4. Remote server

[0109] (1) The remote server is usually set up in the customer's room. Its main functions are remote data acquisition, task distribution and alarm transmission.

[0110] (2) The remote server communicates with the robot body via the 4G / 5G public network.

[0111] Specifically, in conjunction with the appendix Figure 1 The battery heating management system of the overhead line walking robot includes: battery compartment, insulation cotton, heating film, switch driver board, lithium battery, main control board (i.e. MCU), and charging station charging equipment.

[0112] The battery compartment is essentially sealed, but some cable outlets are allowed.

[0113] The insulation material is made of glass wool and is tightly attached to the six sides of the inner wall of the battery compartment. It is used to keep the heating film warm during heating, reduce heat loss through the air and battery compartment, and improve heating efficiency.

[0114] Under the control of the MCU and the driving circuit, the switch driver board turns the power line of the heating film on and off, thereby controlling the heating.

[0115] The heating film is made of silicone rubber, and there are three pieces in total. They are the same size as the left, bottom and right sides of the battery, and are installed close to the battery.

[0116] The battery is a lithium battery using ordinary low-temperature cells, meaning it can discharge below 0°C but cannot be charged. During use, the lithium battery is placed inside a battery compartment lined with insulating cotton. The lithium battery is in a pouch form, containing a battery management system (BMS) and the cells. Each cell has a temperature probe on its surface to collect temperature data and transmit it back to the BMS. The lithium battery communicates with the MCU via a serial port to obtain information such as battery level, voltage, charging / discharging current, and cell temperature.

[0117] The battery BMS includes charging MOSFETs and discharging MOSFETs. The charging MOSFETs enable the switching of the charging circuit of the battery cell, and the discharging MOSFETs enable the switching of the discharging circuit of the battery cell.

[0118] The charging equipment at the charging station is fixed on the pole. Currently, wireless charging is used, but contact charging can also be used.

[0119] The auxiliary control components include: a positioning system, a charging limit switch, a wireless communication module, and a temperature sensor.

[0120] The positioning system uses GPS, which is installed on the robot itself. It communicates with the MCU via the network port to obtain the robot's current latitude and longitude, compares and converts it with previously accumulated data, confirms which two poles the robot is located between, and calculates the distance to the charging point and the return mileage.

[0121] The charging limit switch is a touch-type mechanical limit switch installed on the robot's charging mechanism. Only devices on the charging station can touch it, and then the MCU confirms that the robot has reached the charging position.

[0122] The wireless communication module is divided into two parts: one is the onboard wireless module on the robot control board, and the other is the wireless module on the charging device. The two communicate with each other via 433M or 2.4G wireless. The onboard wireless module communicates with the main control MCU via serial port.

[0123] The temperature sensor probe is placed close to the top surface of the battery to collect the temperature of the top surface of the battery and communicate with the MCU via serial port.

[0124] In an example of this invention, see Figure 2-6 The battery heating management system provided by this invention can be implemented using the following control method:

[0125] Step 1: When the overhead line walking robot is inspecting and walking on the overhead line, it reads the temperature sensor value T1 on the upper surface of the battery attached to the robot every minute; then proceed to step 2.

[0126] Step 2: Determine if the temperature sensor value T1 is less than 0℃. If not, proceed to step 1; if yes, proceed to step 3.

[0127] Step 3: The MCU communicates with the battery, reads the battery BMS information, parses the temperature of each cell sampled by the battery BMS, and compares and obtains the lowest cell temperature T2 and the current battery voltage U1; then proceed to step 4.

[0128] Step 4: Determine if the lowest cell temperature T2 is below 0℃; if not, continue to step 3; if yes, proceed to step 5.

[0129] Step 5: Determine if the temperature sensor value T1 is less than the lowest cell temperature T2; if not, proceed to step 6; if yes, proceed to step 7.

[0130] Step 6: Calculate the temperature difference ΔT between the current temperature and the normal charging temperature of the battery, and ensure that the minimum temperature of the battery cell is 5℃ during charging, i.e., the heating temperature difference ΔT = -T2+5, and continue to step 8.

[0131] Step 7: Calculate the temperature difference ΔT between the current temperature and the normal charging temperature of the battery, and ensure that the minimum temperature of the battery cell is 5℃ during charging, i.e., the heating temperature difference ΔT = -T1 + 5, and continue to step 8.

[0132] Step 8: Since the battery is mostly composed of cells, the specific heat capacity of the battery cell material is c, the total mass of the battery is m, and the thermal insulation coefficient of the battery compartment is α, calculate the energy required to heat the current battery from its current temperature to the battery charging temperature. The total heating energy is W1 = cmΔT / α. Continue to step 9.

[0133] Step 9: The rated heating power of a single heating film is P3. The heating system has three heating films: left, bottom, and right. Calculate the heating time t3 required for the heating film to heat at its rated power: t3 = W1 / P3 / 3; Continue to step 10.

[0134] Step 10: Turn off the MOSFET in the battery charging circuit to cut off the charging circuit and prevent the charging equipment from charging the battery cells in sub-zero conditions; continue to step 11.

[0135] Step 11: Read GPS information every 30 seconds, analyze the robot's current location, calculate the distance S between the robot and the charging point on the pole, and continue to step 12;

[0136] Step 12: Read the robot's running speed v every 30 seconds and calculate the return motion time t1=S / v; based on experience, the robot's average motion power on the overhead line is assumed to be a fixed value P1, and continue to step 13;

[0137] Step 13: Based on the currently analyzed position of the robot, calculate the number of towers that need to be crossed, which is n; based on experience, the time for the robot to cross a single tower is a fixed value t2; based on experience, the average power value for the robot to cross a single tower is a fixed value P2; continue to step 14;

[0138] Step 14: Calculate the total time t for the robot to return at this moment, t = t1 + n * t2; continue to step 15;

[0139] Step 15: Calculate the total power consumption W2 of the robot returning to home at this moment, W2=P1*t1+P2*n*t2; continue to execute step 16;

[0140] Step 16: Calculate the power Q1 required for the robot to return to home at this moment, Q1 = W2 / U1; continue to step 17;

[0141] Step 17: The MCU communicates with the battery, reads the battery BMS information, and reads the current battery level Q2; then proceed to step 18.

[0142] Step 18: Calculate the robot's current remaining battery power Q3. Remaining battery power = current battery power - battery power required for return, i.e., Q3 = Q2 - Q1; Continue to step 19;

[0143] Step 19: Calculate the current surplus energy W3 of the robot's battery, W3 = Q3 * U1; Proceed to Step 20;

[0144] Step 20: Determine whether the robot is moving towards the charging point or away from it. If the robot is moving towards the charging point, proceed to step 26; if the robot is moving away from the charging point, proceed to step 21.

[0145] Step 21: Determine if the remaining power Q3 is less than 15% at this moment; if not, proceed to step 22; if yes, proceed to step 23.

[0146] Step 22: Continue with the current task;

[0147] Step 23: The MCU reports the current battery temperature, cell temperature, battery level, return range, and remaining battery power to the host computer, providing the host computer with a battery level warning. Continue to step 24;

[0148] Step 24: Wait for the host computer to issue a return command; if yes, continue to step 25; if no, continue to step 23.

[0149] Step 25: Upon receiving the return command from the host computer, turn the robot's forward direction; continue to step 26;

[0150] Step 26: Determine if the battery's remaining charge is greater than 5%; if yes, proceed to step 27; if no, proceed to step 31.

[0151] Step 27: Determine whether the total return time t is less than the battery heating time t3; if yes, proceed to step 28; if no, proceed to step 26.

[0152] Step 28: Determine whether the current surplus energy W3 of the robot battery is less than the total energy W1 required for battery heating; if yes, proceed to step 29; if no, proceed to step 30.

[0153] Step 29: The ratio D of surplus energy W3 to the energy required for heating is the PWM output duty cycle D of the MCU; continue to step 32;

[0154] Step 30: The PWM output duty cycle D of the MCU is set to 100%. Proceed to step 32;

[0155] Step 31: The PWM output duty cycle D of the MCU is 0%. Proceed to step 35;

[0156] Step 32: The power supply voltage of the driver board responsible for amplifying the driving capability is 24V, and the output voltage of the driver board is U2, U2=24*D; continue to execute step 33;

[0157] Step 33: The heating power P4 of a single heating film is proportional to the input voltage, P4 = D * P3; continue to step 34;

[0158] Step 34: Turn on the battery heater to preheat the battery; continue to step 36;

[0159] Step 35: Stop battery heating; Proceed to Step 36;

[0160] Step 36: Determine whether the robot charging point limit switch is closed. This limit switch is triggered to close when the robot reaches the charging position. If not, continue to step 26; if yes, proceed to step 37.

[0161] Step 37: The MCU communicates with the wireless module on the charging device via the onboard wireless module (onboard 433M wireless module), reads and parses the charging device information; then proceed to step 38.

[0162] Step 38: Determine if there is charging current output at the output terminal of the charging device; if not, continue to step 37; if yes, proceed to step 39.

[0163] Step 39: Adjust the MCU output duty cycle D=100%, the heating film is at rated power output, and the battery heating is turned on; continue to step 40;

[0164] Step 40: Turn off the battery discharge MOSFET to cut off the battery discharge circuit. At this time, only use the external charging device to power the entire robot to maintain the battery capacity so that the battery can be fully charged faster later and make full use of the time; continue to step 41.

[0165] Step 41: Determine if the temperature of all battery cells is greater than 5°C; if not, continue to step 41; if yes, proceed to step 42.

[0166] Step 42: Determine if the temperature of the battery surface temperature sensor is greater than 5°C; if not, continue to step 42; if yes, proceed to step 43.

[0167] Step 43: Turn on the battery charging MOSFET and discharging MOSFET to start charging the battery, and monitor and upload the battery level in real time.

[0168] The technical solution adopted in this embodiment has the following advantages:

[0169] 1. When the battery surface and cell are below 0°C, the MCU controls the battery to turn off the charging MOSFET, cutting off the charging circuit of the battery cell, and the battery cannot be charged; only when the battery and cell both reach a certain temperature of 0°C or above can the MCU control the battery to turn on the charging MOSFET, so that the external charging device can charge the battery cell.

[0170] 2. The robot's current location is confirmed in real time using GPS and other positioning information. The robot's return distance at this moment is calculated. Based on the current average speed, the robot's return time at this moment is calculated. Then, the energy and battery power required for the robot's return are estimated. Combined with the current battery power, the remaining battery power is obtained. The remaining battery power can be used to provide battery power warnings for the robot, and real-time battery power control is integrated into the robot's inspection operation.

[0171] 3. When the battery surface and cell temperature are below 0°C, the MCU calculates the required temperature increase for the battery in real time, and then converts this into the energy needed to heat the entire battery. This energy is compared with the battery's remaining energy. During the return journey, based on the linear relationship between the battery's energy and the required heating energy, the MCU adjusts the battery heating power in real time to maximize the use of the remaining battery capacity and achieve efficient heating while ensuring the robot's safe return.

[0172] 4. When the battery surface and cells are below 0℃, the temperature that the battery needs to be heated is fixed, and the energy required to heat the entire battery is fixed. With a fixed heating power of the heating film, the heating time is fixed. The robot's return time can only be used to heat the battery continuously if it is less than the heating time. Otherwise, the heating may be interrupted due to insufficient battery power, or the robot may even be stranded due to the battery running out of power.

[0173] 5. Preheat the battery during the robot's return journey so that the residual charge of the battery can be used to heat the battery body during the return journey. Under reasonable conditions, this maximizes the use of the battery and reduces the heating time at the charging station, thereby improving charging efficiency.

[0174] 6. After the robot arrives at the charging station, when the battery surface and cells are below 0°C, the charging equipment detects the battery voltage and starts charging. It then controls the battery to turn off the discharge MOSFET and uses external charging equipment to directly heat the battery until the battery surface and cells are at a certain temperature above 0°C. Only then does it control the battery to turn on the charging MOSFET and discharge MOSFET.

[0175] The present invention and its embodiments have been described above illustratively. This description is not restrictive, and the figures shown are only one embodiment of the present invention; the actual structure is not limited thereto. Therefore, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A battery heating management system for an overhead line walking robot, wherein the robot walks on an overhead line erected by poles via a walking mechanism to inspect and / or perform operations on the overhead line, the robot is charged via a charging device installed at a fixed charging position on the pole, and the robot is equipped with a battery for storing and releasing electrical charge, characterized in that... The battery heating management system includes: a battery compartment located on the robot for storing batteries; A heating film for heating the battery is provided inside the battery compartment; Temperature sensor used to collect battery surface temperature and battery cell temperature; The main control board is used for communication control of the battery. The main control board communicates with the battery BMS and is connected to the temperature sensor signal. The main control board controls the heating film to heat up or stop heating through the switch driver board according to the signal of the temperature sensor. as well as, A wireless communication module is used for wireless connection between the charging device and the main control board of the robot, and the main control board obtains information about the charging device through the wireless communication module. A positioning system is used to confirm the robot's current location and calculate the mileage required for the robot to return to the charging location based on the confirmed current location information. The battery heating control method of the battery heating management system includes: Step 1: Collect the temperature of the upper surface of the battery through the temperature sensor. When the temperature sensor value T1 is lower than 0℃, the main control board communicates with the battery, reads the battery BMS information, analyzes the temperature of each cell sampled by the battery BMS, and compares and obtains the lowest cell temperature T2 and the current battery voltage U1. Step 2: Determine whether T1 is less than T2 when T2 is below 0℃. If not, continue to step 3; if yes, proceed to step 4. Step 3: Calculate the temperature difference ΔT between the current battery temperature and the normal charging temperature of the battery to ensure that the minimum cell temperature is 5℃ during charging, i.e., heating temperature difference ΔT = -T2 +5; Step 4: Calculate the temperature difference ΔT between the current battery temperature and the normal charging temperature of the battery to ensure that the minimum cell temperature is 5℃ during charging, i.e., heating temperature difference ΔT = -T1 +5.

2. The battery heating management system for the overhead line walking robot according to claim 1, characterized in that, It also includes a switch driver board for controlling the switching of the heating film. The switch driver board is a PWM-controlled switch driver board. The main control board is connected to the switch driver board. The main control board controls the switch driver board to turn the heating film on or off according to the signal from the temperature sensor.

3. The battery heating management system for the overhead line walking robot according to claim 1, characterized in that, It also includes insulation cotton disposed inside or outside the battery compartment for keeping the battery warm, the insulation cotton being arranged to be tightly attached to the six sides of the battery compartment.

4. The battery heating management system for the overhead line walking robot according to claim 1, characterized in that, The wireless communication module includes a wireless module located in the charging device and a wireless module located on the main control board, both of which communicate wirelessly via Bluetooth or 433M.

5. The battery heating management system for the overhead line walking robot according to claim 1, characterized in that, The robot is equipped with a robot-side charging port electrically connected to the battery for charging the battery. The battery has a charging port and a discharging port. The robot-side charging port is connected to the charging port of the battery, and the charging port of the charging device is connected to the output port of the charging device.

6. The battery heating management system for the overhead line walking robot according to claim 1, characterized in that, It also includes the following steps: Step 5: Calculate the energy required to heat the battery from its current temperature to its charging temperature. The total heating energy is W1 = cmΔT / α, where c is the specific heat capacity of the battery cell material, m is the total mass of the battery, and α is the battery compartment insulation coefficient. Define three heating films on the left, bottom, and right sides of the battery. Define the rated heating power of each heating film as P3. Calculate the heating time t3 required to heat the film at its rated power. t3 = W1 / P3 / 3. Step 6: Disconnect the battery charging circuit to prevent the charging equipment from charging the battery cells in sub-zero conditions; Step 7: Read the positioning information from the positioning system, analyze the robot's current location, and calculate the distance S between the robot and the charging location; Step 8: Read the robot's running speed v, and calculate the return motion time t1 = S / v; Step 9: Set the average power of the robot's movement to P1. Based on the currently analyzed position of the robot, calculate the number of poles that need to be crossed, n. Set the time for the robot to cross a single pole to t2. The average power of the robot crossing a single pole is P29. Calculate the total time t for the robot to return at this moment, t = t1 + n * t2. Calculate the total power consumption W2 for the robot to return at this moment, W2 = P1 * t1 + P2 * n * t2. Calculate the battery power Q1 required for the robot to return at this moment, Q1 = W2 / U1. Step 10: The main control board communicates with the battery, reads the battery BMS information, and reads the current battery level Q2; Step 11: Calculate the current remaining battery power Q3 of the robot, Q3 = Q2 - Q1; Step 12: Calculate the current surplus energy W3 of the robot's battery, W3 = Q3 * U1; Step 13: Determine whether the robot is moving towards the charging position or away from it. If the robot is moving away from the charging position, then when Q3 is less than 15%, the main control board reports the battery temperature, cell temperature, battery level, return range, and remaining battery level to the host computer to provide a battery level warning.

7. The battery heating management system for the overhead line walking robot according to claim 6, characterized in that, It also includes the following steps: Step 14: Determine whether the robot is moving towards the charging position or away from it. If the robot is moving towards the charging position, determine whether the battery has more than 5% remaining charge. If yes, proceed to step 15; otherwise, proceed to step 19. Step 15: Determine whether the total return time t is less than the battery heating time t3; if yes, proceed to step 16; if no, proceed to step 14. Step 16: Determine whether the current surplus energy W3 of the robot battery is less than the total energy W1 required for battery heating; If yes, proceed to step 17; otherwise, proceed to step 18. Step 17: Calculate the PWM output duty cycle D of the main control board, D = W3 / W1, and continue to step 20; Step 18: The PWM output duty cycle D of the main control board is 100%, continue to execute step 20; Step 19: The PWM output duty cycle D of the main control board is 0%, continue to step 23; Step 20: The power supply voltage of the driver board responsible for amplifying the driving capability is 24V, and the output voltage of the driver board is U2, U2=24*D. Continue to execute step 21. Step 21: The heating power P4 of a single heating film is proportional to the input voltage, P4=D*P3, continue to step 22; Step 22: Turn on the battery heater to preheat the battery; Step 23: Stop battery heating.

8. The battery heating management system for the overhead line walking robot according to claim 7, characterized in that, It also includes the following steps: Step 24: Determine whether the robot charging position limit switch is closed and whether the robot has reached the charging position. If so, the control board communicates with the charging equipment through the wireless communication module to read and parse the charging information. Step 25: Determine if there is charging current output at the output terminal of the charging device. If yes, proceed to step 26. Step 26: Adjust the main control board output duty cycle D=100%, the heating film is at rated power output, and the battery heating is turned on.

9. The battery heating management system for the overhead line walking robot according to claim 8, characterized in that, It also includes the following steps: Step 27: Disconnect the battery discharge circuit and use only the charging device to power the robot, then continue to step 28; Step 28: Determine if the temperature of all battery cells is greater than 5°C. If so, proceed to step 29. Step 29: Determine whether the temperature of the battery surface temperature sensor is greater than 5°C. If so, proceed to step 30. Step 30: Charge the battery and monitor and upload the battery level in real time.

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