A monitoring method and monitoring device for high-temperature life testing of a lead-acid battery

Abstract

This invention is entitled "Monitoring Method and Device for High-Temperature Life Testing of Lead-Acid Batteries." The monitoring device measures the positive plate grid height and predicts the high-temperature lifespan, allowing users to identify potential high-temperature lifespan failure risks in advance and replace the battery, thus preventing vehicle starting failure due to battery use. The monitoring device includes an ultrasonic signal processor, ultrasonic output signal lines, ultrasonic output probes, ultrasonic receiving probes, ultrasonic receiving signal lines, fixing rings, fixing clips, etc. This invention can identify whether the positive plate has grown beyond the separator, determining whether the high-temperature lifespan of the lead-acid battery is at risk.

Description

Technical Field

[0001] This invention belongs to the field of lead-acid battery testing technology, specifically relating to a monitoring method and device for high-temperature life testing of lead-acid batteries. Background Technology

[0002] When batteries operate in high-temperature environments, their lifespan decreases rapidly with increasing temperature. The internal grid plates corrode and age quickly at high temperatures, leading to premature battery termination. The high-temperature lifespan test for lead-acid batteries simulates the corrosion resistance of the battery's internal positive plates in the high-temperature environment of an engine compartment.

[0003] After lead-acid batteries undergo high-temperature life testing, the current method involves dissecting and analyzing the battery to determine the growth status of the internal electrode assembly and plates. Without this dissection, the internal condition of the battery cannot be accurately determined. Later in the battery's lifespan, it may suddenly fail to meet the vehicle's starting and power supply requirements, resulting in the vehicle failing to start or a poor user experience. Summary of the Invention

[0004] In view of the problem in the background technology that the positive plate grid of lead-acid batteries grows and causes battery failure, the purpose of this invention is to provide a monitoring method for high-temperature life testing of lead-acid batteries. Through real-time monitoring, this invention can measure the height of the positive plate grid inside the battery and predict the failure of the high-temperature life battery in a timely manner. This allows users to identify the risk of high-temperature life failure of lead-acid batteries in advance, replace the batteries, and avoid the vehicle being unable to start due to battery failure during vehicle use.

[0005] Another object of the present invention is to provide a monitoring device.

[0006] The present invention provides a monitoring method for high-temperature life testing of lead-acid batteries, characterized by comprising the following steps:

[0007] 1) Determine the size of the retaining ring based on the external dimensions of the battery to be tested;

[0008] 2) Determine the size and position M of the circle in the fixing ring near the negative terminal: Draw the structural diagram of the battery before deformation and the structural diagram after deformation. According to the structural diagram after deformation, obtain the trajectory line m of the growth of the positive plate grid. According to the structural diagram before deformation, determine the vertical distance L between the upper surface of the separator of the battery under test and the outer side of the bottom of the negative terminal of the battery under test. With the length of the vertical distance L as the radius, and with the outer side of the bottom of the negative terminal and the upper surface of the separator as the two tangent points of the circle, draw a circle C1. The tangent point of circle C1 and the negative terminal is the short circuit point. According to the coordinates of the center of circle C1, determine the center position of the ultrasonic sensor probe outside the battery casing. Combined with the radius r of the ultrasonic sensor probe, draw circle C2. Circle C2 is the inner ring cross section of the circular fixing ring used to fix the ultrasonic sensor probe on the fixing ring.

[0009] 3) Determine the size of the fixing buckle and the fixing position of the fixing ring outside the battery casing according to position M, and set a circular fixing ring on the fixing ring;

[0010] 4) Surveillance

[0011] When using the penetration ultrasonic detection method for monitoring, the position N of the fixed ring near the positive terminal is determined based on position M. The fixed ring fixes the ultrasonic output probe on one side to the negative terminal side of the battery tank, and the fixed ring fixes the ultrasonic receiving probe on the positive terminal side of the battery tank, with the fixed ring fastened to the mounting bracket of the tank. The ultrasonic output probe, ultrasonic receiving probe and fixed ring are concentric. The ultrasonic signal processor transmits the ultrasonic signal A to the ultrasonic output probe through the ultrasonic output signal line. The ultrasonic receiving probe receives the ultrasonic signal B on the other side of the lead-acid battery and returns the signal to the ultrasonic signal processor through the ultrasonic receiving signal line for ultrasonic signal energy loss diagnosis.

[0012] It also includes verification: the verification area outside the battery casing to be tested is determined according to the coordinates of the trajectory line m of the positive plate grid growth. The ultrasonic sensor probe is moved along the verification area, and the ultrasonic waveform displayed in the ultrasonic signal processor is observed. The degree of deformation of the positive plate grid can be judged according to the scattering attenuation of the ultrasonic waveform. When the ultrasonic sensor probe is placed at the circle C2 position, the ultrasonic scattering attenuation is greater than that at other positions on the trajectory line m of the positive plate grid growth.

[0013] The ultrasonic output probe has an ultrasonic frequency of 0.25~25MHz.

[0014] A monitoring method for high-temperature life testing of lead-acid batteries includes the following steps:

[0015] 1) Determine the size of the retaining ring based on the external dimensions of the battery to be tested;

[0016] 2) Determine the size and position M of the circle in the fixing ring near the negative terminal: Draw the structural diagram of the battery before deformation and the structural diagram after deformation. According to the structural diagram after deformation, obtain the trajectory line m of the growth of the positive plate grid. According to the structural diagram before deformation, determine the vertical distance L between the upper surface of the separator of the battery under test and the outer side of the bottom of the negative terminal of the battery under test. With the length of the vertical distance L as the radius, and with the outer side of the bottom of the negative terminal and the upper surface of the separator as the two tangent points of the circle, draw a circle C1. The tangent point of circle C1 and the negative terminal is the short circuit point. According to the coordinates of the center of circle C1, determine the center position of the ultrasonic sensor probe outside the battery casing. Combined with the radius r of the ultrasonic sensor probe, draw circle C2. Circle C2 is the inner ring cross section of the circular fixing ring used to fix the ultrasonic sensor probe on the fixing ring.

[0017] 3) Determine the size of the fixing buckle and the fixing position of the fixing ring outside the battery casing according to position M, and set a circular fixing ring on the fixing ring;

[0018] 4) Surveillance

[0019] When using the pulse-echo ultrasonic detection method for monitoring, an ultrasonic sensor probe is placed at a fixed ring, and an ultrasonic signal processor is connected to the ultrasonic sensor probe through a signal line to perform ultrasonic signal energy loss diagnosis.

[0020] Verification: Determine the verification area outside the battery casing to be tested based on the coordinates of the trajectory line m of the positive electrode grid growth. Move the ultrasonic sensor probe along the verification area and observe the ultrasonic waveform displayed in the ultrasonic signal processor. The degree of deformation of the positive electrode grid can be determined based on the scattering and attenuation of the ultrasonic waveform. When the ultrasonic sensor probe is placed at position C2, the scattering and attenuation of the ultrasonic wave is greater than at other positions on the trajectory line m of the positive electrode grid growth.

[0021] A monitoring device for high-temperature life testing of lead-acid batteries includes an ultrasonic signal processor, an ultrasonic output signal line, an ultrasonic output probe, an ultrasonic receiving probe, an ultrasonic receiving signal line, a fixing ring, a fixing buckle, and a fixing buckle. The ultrasonic output probe and the ultrasonic receiving probe are symmetrically positioned and respectively fixed on the fixing ring. The fixing ring fixes one side of the ultrasonic output probe to the negative terminal side of the battery tank, and the fixing ring fixes the other side of the ultrasonic output probe to the positive terminal side of the battery tank. The fixing buckle is attached to the mounting bracket of the tank. The ultrasonic output probe, the ultrasonic receiving probe, and the fixing ring are concentric. The ultrasonic signal processor transmits ultrasonic signal A to the ultrasonic output probe through the ultrasonic output signal line. The ultrasonic receiving probe receives ultrasonic signal B on the other side of the lead-acid battery and returns the signal to the ultrasonic signal processor through the ultrasonic receiving signal line for ultrasonic signal energy loss diagnosis.

[0022] The fixing ring, fixing buckle, and fixing buckle are made of acid-resistant material, and an acid-resistant outer shell can be added if necessary.

[0023] This invention relates to a method for testing the high-temperature life failure of lead-acid batteries, characterized by comprising a battery, an ultrasonic signal processor, an ultrasonic output signal line, an ultrasonic output probe, an ultrasonic receiving probe, an ultrasonic receiving signal line, a fixing ring, a fixing buckle, etc. The ultrasonic signal processor transmits ultrasonic signal A to the ultrasonic output probe via the ultrasonic output signal line; the ultrasonic receiving probe receives ultrasonic signal B on the other side of the lead-acid battery and returns the signal to the ultrasonic signal processor via the ultrasonic receiving signal line for ultrasonic signal energy loss diagnosis (AB). The ultrasonic output probe is concentric with the fixing ring, which fixes the ultrasonic output probe to the negative terminal side of the battery casing. The fixing buckle is attached to the casing's mounting lugs, ensuring the fixing ring is positioned vertically.

[0024] The ultrasonic detection method described in the technical solution of this invention can be the pulse reflection method or the penetration method, with the penetration method being preferred. This method determines the defect based on the energy change after a pulse wave or continuous wave penetrates the specimen. The penetration method typically uses two probes, one for receiving and one for transmitting, placed on opposite sides of the specimen for detection.

[0025] The ultrasonic frequency described in the technical solution of the present invention is 0.25~25MHz, preferably 0.25~1MHz.

[0026] The ultrasonic probe position described in the technical solution of this invention is the position when the positive electrode grid grows beyond the separator, which can be determined according to the different design dimensions of the lead-acid battery.

[0027] The component material described in the technical solution of the present invention is preferably an acid-resistant material, and an acid-resistant outer shell may be added if necessary.

[0028] According to the inventors' research, during high-temperature life testing of lead-acid batteries, the failure mode is the corrosion and growth of the positive grid, leading to a short circuit between the positive and negative plates in a single cell. During charge and discharge cycles, the linear dimensions of the positive grid increase; this change is called "grid deformation." Lead-acid battery grids are designed with off-center lugs, with the lugs and busbars fixed to one side of the centerline. During charge and discharge cycles, the grid grows, and the upper edge of the grid gradually deforms into a "U" shape. Due to the position of the lugs, the grid on the side furthest from the positive lug grows more. For lead-acid batteries, during high-temperature life testing, the positive grid in the cell containing the negative terminal will connect to the bottom of the negative terminal post earlier after growth, posing the greatest risk of a short circuit and leading to battery failure. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram illustrating the principle of the present invention.

[0031] Figure 2 This is a schematic diagram of the fixing ring structure of the present invention.

[0032] Figure 3 This is a schematic diagram showing the state of the present invention fixed on a lead-acid battery.

[0033] In the diagram: 1. Ultrasonic signal processor; 2. Ultrasonic output signal line; 3. Ultrasonic output probe; 5. Ultrasonic receiving signal line; 6. Fixing ring; 7. Fixing buckle; 8. Lead-acid battery; 9. Positive plate; 10. Separator; 11. Negative terminal post. Detailed Implementation

[0034] The following is through Figure 3 The technical solutions (including preferred technical solutions) of the present invention are further described in detail by listing some optional embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of this patent.

[0035] like Figure 1 As shown, this invention discloses a high-temperature life failure early warning device for lead-acid batteries, comprising an ultrasonic signal processor 1, an ultrasonic output signal line 2, an ultrasonic output probe 3, an ultrasonic receiving probe, an ultrasonic receiving signal line 5, a fixing ring 6, a fixing ring 7, and a fixing buckle 8. The ultrasonic signal processor 1 transmits ultrasonic signal A to the ultrasonic output probe 3 via the ultrasonic output signal line 2. The ultrasonic receiving probe receives ultrasonic signal B on the other side of the lead-acid battery 9 and returns the signal to the ultrasonic signal processor 1 via the ultrasonic receiving signal line 5 for ultrasonic signal energy loss diagnosis (AB). The ultrasonic output probe 3 and the ultrasonic receiving probe are symmetrically positioned and fixed to the fixing ring 7. The fixing ring 7 fixes one side of the ultrasonic output probe 3 to the negative terminal side of the battery tank, and the fixing ring 7 fixes the other side of the ultrasonic output and receiving probe to the positive terminal side of the battery tank. The fixing buckle 8 is attached to the mounting bracket of the tank, ensuring the vertical position of the fixing ring 6.

[0036] like Figure 1As shown, during high-temperature life testing of lead-acid battery 9, the positive plate 10 grows and deforms, exceeding the separator 11, and eventually contacts the negative terminal 12, forming a short circuit. The purpose of this invention is to detect whether the positive plate 10 has grown beyond the separator 11. If it does, the ultrasonic signal will be blocked by the positive plate 10, resulting in scattering and attenuation of the ultrasonic waves. The energy attenuation (AB) will differ from the initial value by approximately 5 dB. Based on the change in energy attenuation (AB), it can be determined whether the positive plate 10 has grown beyond the separator 11, thus identifying high-temperature lifespan risks.

[0037] like Figure 2 As shown, the fixing ring 6 is provided with a fixing ring 7 and a fixing buckle 8. If the penetration method is used, there are two fixing rings 7 and two fixing buckles 8, which are placed on both sides of the lead-acid battery 9 respectively; if the pulse reflection method is used, there is one fixing ring 7 and two fixing buckles 8, both placed on the negative terminal side of the lead-acid battery 9.

[0038] Ultrasonic probe placement design: such as Figure 1 As shown, after the electrode plates are cast and welded, the positions of the plate ears are fixed. During the high-temperature lifespan of the electrode plates, since there is no fixed point, the position of the electrode plate frame will gradually deform into a "U" shape as the grid grows. Due to the influence of the plate ear position, the grid on the side farther from the positive electrode ear will grow more. At the same time, the vertical distance between the negative electrode post 12 and the separator 11 is a fixed value after battery production. Therefore, taking the distance between the bottom right corner of the negative electrode post 12 (i.e., point A on the outer side of the bottom of the negative electrode post 12) and the position on the upper surface of the separator 11 as the radius, and taking the point on the outer side of the bottom of the negative electrode post 12 and a point on the upper surface of the separator 11 as the two tangent points of the circle, draw a circle C1. The contact point between circle C1 and the negative electrode post 12 is the short circuit point, which is point A on the outer side of the bottom of the negative electrode post 12. The position of the circle is the installation position of the ultrasonic output probe 3 and the ultrasonic receiving probe. According to the size of the ultrasonic output probe 3 and the ultrasonic receiving probe, the center position of the ultrasonic output probe 3 and the ultrasonic receiving probe is determined according to the center of circle C1.

[0039] Fixed ring position design: such as Figure 2 As shown, the fixing ring 6 is equipped with a fixing ring 7. Since the center positions of the ultrasonic output probe 3 and the ultrasonic receiving probe directly affect the accuracy of this measurement method, the fixing ring 7 must be designed to be concentric with the ultrasonic output probe 3 and the ultrasonic receiving probe to ensure detection accuracy. The fixing ring 6 is also equipped with a fixing buckle 8, which is fixed to the side flap of the battery (e.g., ...). Figure 3 As shown, the upper and lower installation positions of the fixing buckle 8 can be set according to the center positions of the ultrasonic output probe 3 and the ultrasonic receiving probe.

[0040] During high-temperature life testing of lead-acid battery 9, as the test cycle extends, the positive plate 10 grows and deforms, extending beyond the separator 11 and eventually contacting the negative terminal 12, causing a short circuit. The testing method of this invention involves installing a retaining ring (such as...) on the battery surface. Figure 2 As shown in the diagram, the positions of the ultrasonic output probe 3 and the ultrasonic receiving probe are those where the positive electrode grid grows beyond the separator. Then, the ultrasonic output probe 3 and the ultrasonic receiving probe are fixed on the fixing ring 7 respectively. During the test, as the battery's high-temperature lifespan decreases, the positive electrode plate 10 will grow to different degrees. If it exceeds the separator 11, the ultrasonic signal will be blocked by the positive electrode plate 10, and the ultrasonic wave will scatter and attenuate. The energy attenuation (AB) will differ from the initial value by about 5dB, which will provide an early warning, reminding that the internal grid of the battery has grown beyond the separator position. Continued use will lead to battery failure. The battery can be replaced in advance to avoid vehicle failure or poor user experience caused by battery failure in the later stages of its lifespan.

[0041] During calibration: Determine the calibration area outside the battery casing to be tested based on the coordinates of the trajectory line m of the positive electrode grid growth. Move the ultrasonic sensor probe along the calibration area and observe the ultrasonic waveform displayed in the ultrasonic signal processor 1. The degree of deformation of the positive electrode grid can be determined based on the scattering and attenuation of the ultrasonic waveform. When the ultrasonic sensor probe is placed at position C2, the scattering and attenuation of the ultrasonic wave is greater than at other positions on the trajectory line m of the positive electrode grid growth.

[0042] It will be readily understood by those skilled in the art that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, combinations, substitutions, improvements, etc., made under the spirit and principles of the present invention are included within the protection scope of the present invention.

Claims

1. A monitoring device for high-temperature life testing of lead-acid batteries, characterized in that: The device includes an ultrasonic signal processor (1), an ultrasonic output signal line (2), an ultrasonic output probe (3), an ultrasonic receiving probe, an ultrasonic receiving signal line (5), a fixing ring (6), a fixing ring (7), and a fixing buckle (8). The ultrasonic output probe (3) and the ultrasonic receiving probe are symmetrically positioned and fixed on the fixing ring (7). The fixing ring (7) fixes one side of the ultrasonic output probe (3) to the negative side of the battery tank and the other side of the ultrasonic receiving probe to the positive side of the battery tank. The fixing buckle (8) is attached to the mounting bracket of the tank. The ultrasonic output probe (3) and the ultrasonic receiving probe are concentric with the fixing ring. The ultrasonic signal processor (1) transmits the ultrasonic signal A to the ultrasonic output probe (3) through the ultrasonic output signal line (2). The ultrasonic receiving probe receives the ultrasonic signal B on the other side of the lead-acid battery and returns the signal to the ultrasonic signal processor through the ultrasonic receiving signal line (5). 1) Perform ultrasonic signal energy loss diagnosis; the position of the fixing ring is determined as follows: determine the size and position M of the circle in the fixing ring (7) near the negative terminal (12): draw the structural diagram of the battery before deformation and the structural diagram after deformation, obtain the trajectory line m of the positive plate grid growth according to the structural diagram after deformation, determine the vertical distance L between the upper surface of the separator (11) of the battery under test and the bottom outer side of the negative terminal (12) of the battery under test according to the structural diagram before deformation, take the length of the vertical distance L as the radius, take the point A at the bottom outer side of the negative terminal (12) and the upper surface of the separator (11) as the two tangent points of the circle, draw a circle C1, the contact tangent point of circle C1 with the negative terminal (12) is the short circuit point, determine the center position of the ultrasonic sensor probe outside the battery shell according to the coordinates of the center of circle C1, draw circle C2 in combination with the radius r of the ultrasonic sensor probe, circle C2 is the inner ring section of the fixing ring (7) on the fixing ring (6) used to fix the ultrasonic sensor probe.

2. The monitoring device for high-temperature life testing of lead-acid batteries according to claim 1, characterized in that: The fixing ring (6), fixing ring (7), and fixing buckle (8) are made of acid-resistant material.

3. A monitoring method for high-temperature life testing of lead-acid batteries, employing the device as described in claim 1, characterized in that: Includes the following steps: 1) Determine the size of the fixing ring (6) based on the external dimensions of the battery to be tested; 2) Determine the size of the fixing buckle (8) and the fixing position of the fixing ring (6) outside the battery casing to be tested according to the position M, and set the fixing ring (7) on the fixing ring (6); 3) Surveillance When using the penetration ultrasonic detection method for monitoring, the position N of the circular fixed ring (7) near the positive terminal is determined according to the position M; the fixed ring (7) fixes the ultrasonic output probe (3) on one side to the negative terminal side of the battery tank, and the fixed ring (7) fixes the ultrasonic receiving probe on the other side to the positive terminal side of the battery tank, and the fixing buckle (8) is hung at the tank flap; the ultrasonic output probe (3), the ultrasonic receiving probe and the fixed ring are concentric, and the ultrasonic signal processor (1) transmits the ultrasonic signal A to the ultrasonic output probe (3) through the ultrasonic output signal line (2); the ultrasonic receiving probe receives the ultrasonic signal B on the other side of the lead-acid battery and returns the signal to the ultrasonic signal processor (1) through the ultrasonic receiving signal line (5) to perform ultrasonic signal energy loss diagnosis.

4. The monitoring method for high-temperature life testing of lead-acid batteries according to claim 3, characterized in that: It also includes verification: the verification area outside the battery casing to be tested is determined according to the coordinates of the trajectory line m of the positive plate grid growth. The ultrasonic sensor probe is moved along the verification area and the ultrasonic waveform displayed in the ultrasonic signal processor (1) is observed. The degree of deformation of the positive plate grid can be judged according to the scattering attenuation of the ultrasonic waveform. When the ultrasonic sensor probe is placed at the circle C2 position, the ultrasonic scattering attenuation is greater than that at other positions on the trajectory line m of the positive plate grid growth.

5. The monitoring method for high-temperature life testing of lead-acid batteries according to claim 3, characterized in that: The ultrasonic output probe has an ultrasonic frequency of 0.25~25MHz.

6. A monitoring method for high-temperature life testing of lead-acid batteries, characterized in that: The monitoring device used in the monitoring method includes an ultrasonic signal processor (1), an ultrasonic sensor probe, a fixing ring (6), a fixing ring (7), and a fixing buckle (8); the fixing ring (7) fixes an ultrasonic sensor probe to the positive / negative side of the battery tank, and the fixing buckle (8) hangs on the tank's flap; the monitoring method includes the following steps: 1) Determine the size of the fixing ring (6) based on the external dimensions of the battery to be tested; 2) Determine the size and position M of the circle in the fixing ring (7) near the negative terminal post (12): Draw the structural diagram of the battery before deformation and the structural diagram after deformation. According to the structural diagram after deformation, obtain the trajectory line m of the growth of the positive plate grid. According to the structural diagram before deformation, determine the vertical distance L between the upper surface of the separator (11) of the battery and the bottom outer side of the negative terminal post (12) of the battery. With the length of the vertical distance L as the radius, take the point A at the bottom outer side of the negative terminal post (12) and the upper surface of the separator (11) as the two tangent points of the circle, draw a circle C1. The contact tangent point of circle C1 with the negative terminal post (12) is the short circuit point. According to the coordinates of the center of circle C1, determine the center position of the ultrasonic sensor probe outside the battery casing. Combine the radius r of the ultrasonic sensor probe to draw circle C2. Circle C2 is the inner ring section of the circular fixing ring (7) on the fixing ring (6) used to fix the ultrasonic sensor probe. 3) Determine the size of the fixing buckle (8) and the fixing position of the fixing ring (6) outside the battery casing to be tested according to the position M, and set the circular fixing ring (7) on the fixing ring (6); 4) Surveillance When using the pulse reflection ultrasonic detection method for monitoring, an ultrasonic sensor probe is placed at a fixed ring (7), and the ultrasonic signal processor (1) is connected to an ultrasonic sensor probe through a signal line to perform ultrasonic signal energy loss diagnosis. Verification: Determine the verification area outside the battery casing to be tested based on the coordinates of the trajectory line m of the positive plate grid growth. Move the ultrasonic sensor probe along the verification area and observe the ultrasonic waveform displayed in the ultrasonic signal processor (1). Based on the scattering attenuation of the ultrasonic waveform, the degree of deformation of the positive plate grid can be determined. When the ultrasonic sensor probe is placed at the circle C2 position, the ultrasonic scattering attenuation is greater than that at other positions on the trajectory line m of the positive plate grid growth.

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