A power system for an explosion-proof truck

Abstract

The application relates to a power system for an explosion-proof carrier, and belongs to the field of power system design. The system comprises a central control explosion-proof box, a battery heating module, a DC 220V direct current power supply, an explosion-proof battery pack, an explosion-proof motor driver, an explosion-proof display and a charger. The application effectively solves the problems of low-temperature charging difficulty, short endurance time, poor battery pack data acquisition and equalization management effect and improper control strategy of the existing carrier, and realizes advanced reliability, controllable risk and long service life.

Description

TECHNICAL FIELD

[0001] The application belongs to the field of power systems, and relates to a power system for an explosion-proof carrier. BACKGROUND

[0002] The explosion-proof carrier for ships needs to be used on a ship at sea and needs to overcome many unfavorable factors on the sea. Meanwhile, in the actual use process, the existing carrier has problems such as difficulty in low-temperature charging, short endurance time, poor data acquisition and equalization management effect of the battery pack, and improper control strategy, which need to be solved urgently. SUMMARY

[0003] The application aims to provide a power system for an explosion-proof carrier to solve the problems such as difficulty in low-temperature charging, short endurance time, poor data acquisition and equalization management effect of the battery pack, and improper control strategy of the existing carrier.

[0004] In order to solve the above technical problems, the application provides a power system for an explosion-proof carrier, which comprises a central control explosion-proof box, a battery heating module, a DC220V direct current power supply, an explosion-proof battery pack, an explosion-proof motor driver, an explosion-proof display and a charger.

[0005] The central control explosion-proof box adopts HWBMS-001 and is connected with the battery heating module, the DC220V direct current power supply, the explosion-proof battery pack, the explosion-proof motor driver, the explosion-proof display and the charger, and is used for completing battery pack state monitoring, up and down power action decision execution and system self-checking.

[0006] The battery heating module adopts DC220V power supply and is connected with the explosion-proof battery pack, and is used for heating the battery.

[0007] The explosion-proof battery pack comprises a first battery pack and a second battery pack, each of which adopts a 16-cell series connection mode and is used for providing power for the carrier.

[0008] The input voltage of the motor driver is DC36-48V, and the maximum current is 150A, and the motor driver is used for driving the motor.

[0009] The explosion-proof display adopts a DC12V power supply interface and an RS485 communication interface.

[0010] The charger is used for charging the explosion-proof battery pack, and the input is AC220V and the output is DC48V.

[0011] The working process of the system comprises the following steps.

[0012] S1, the system is powered on by rotating the knob switch on the carrier, and if the power-on is normal, the display power supply indicator light is green.

[0013] S2, after the system is normally powered on, the system performs a whole vehicle state parameter self-check, after the self-check is completed, the display displays the state information of the battery pack;

[0014] S3, the rotating motor start / stop button, the motor power supply is normal, the forward / reverse and speed control is performed through the vehicle body manual lever, and the display real-time checks the battery pack state parameters;

[0015] S4, insert the charging gun, the main display displays the battery pack charging state, the system defaults the first battery pack to be charged preferentially, the display shows that the first battery pack is in a charging state, when the battery power reaches a preset state, the system automatically switches to the second battery pack for charging;

[0016] S5, pull out the charging gun, the system defaults the second battery pack to be discharged preferentially, the display shows that the second battery pack is in a discharging state, when the battery power reaches a preset state, the system switches to the first battery pack for discharging;

[0017] S6, when both battery packs are in a deficit state, the discharge contactors are in an open state, the emergency home switch on the rotating carrier is turned on, the system forcibly closes the battery pack to supply power to the motor controller, and the main display displays a battery health state serious warning information.

[0018] Further, the central control explosion-proof box comprises a box body, a BMS, a DC12V direct current power supply, a Hall current sensor, a contactor, a relay and a power resistor, and the central control explosion-proof box has a bus voltage input / output interface, a cell temperature voltage acquisition interface, a display communication interface and a load power supply interface.

[0019] Further, the box body and the box cover of the central control explosion-proof box are respectively welded and formed by low-alloy steel plates with thicknesses of 12 mm and 8 mm, and the box body and the box cover are tightly connected by bolts; the central control explosion-proof box uses an explosion-proof packing gland, the packing gland is installed on the left and right sides of the box body, the left and right sides of the box body are provided with mounting hole positions at the bottom, so that the equipment and the bracket are conveniently installed; the equipment nameplate is arranged on the box cover and is made of brass.

[0020] Further, the BMS is composed of one battery main control unit BCU and two battery front-end acquisition and management units BMU1 and BMU2, the DC12V direct current power supply and the BCU are installed in the box body, and the BMU is installed on the side of the box body.

[0021] Further, BMU1 corresponds to the first battery pack, BMU2 corresponds to the second battery pack, BMU completes the voltage and temperature detection of the single battery in the battery pack corresponding to each, SOC and SOH calculation, and reports the detection and calculation data to BCU through the internal communication bus. BCU detects the external emergency return home signal, performs state evaluation on the system working condition according to the detection results and the battery temperature and voltage data uploaded by BMU, and performs comprehensive management, scheduling and charge-discharge management.

[0022] Further, BCU selects STM32F105RBT6 of ST Company, and the main control chip of BMU selects MPC5744P digital signal processing chip of NXP Company.

[0023] Further, SOC calculation needs to model the battery by an electrochemical model, establish a simulation battery pack internal structure physical and electrical model, construct partial differential equations of battery state according to physical principles such as solid matter conservation and charge conservation, electrolyte liquid matter conservation and charge conservation, and electrode reaction kinetics, solve the equations, and solve the equation set by using the non-polar Kalman filtering algorithm, and finally obtain the lithium ion concentration in the positive and negative solid phase and electrolyte liquid phase, which is SOC. When calculating SOC, the highest and lowest power cells in the current battery pack are used for SOC calculation, and the average is obtained to obtain the SOC of the whole pack.

[0024] Further, when calculating SOH, based on the battery data collected by BMU in real time, the aging parameters affecting the battery performance are analyzed for parameter sensitivity based on the electrochemical model of the battery, and the capacity and health status information of the battery are obtained through these electrochemical aging parameters, that is, SOH.

[0025] Further, the BMS software includes BMU software, BCU software and display software; the BMU software includes data acquisition, state evaluation, equalization management, charger state detection, fault handling, self-checking, data interaction software, the BCU software includes peripheral control, self-checking, data storage, data processing, alarm fault judgment, data interaction software, and the display software includes battery pack information display interface, system self-checking display interface and fault display interface; the BCU control software connects BMU1 software and BMU2 software through CAN, and connects display software through RS485; BMU1 software obtains first battery pack bus voltage, current, first battery pack single battery voltage, temperature and charger signal, and BMU2 software obtains second battery pack bus voltage, current, second battery pack single battery voltage, temperature and charger signal.

[0026] Further, the box body of the central control explosion-proof box is fully welded with aluminum material, the printed matter is treated with three-proofing, the connector wiring end is filled and sealed, the whole is designed as a sealed design to prevent water vapor and salt mist from entering the box; high-strength metal material is adopted, and stress concentration is avoided in the structural design to resist the impact force transmitted by the ship body structure; the outer surface of the case is coated with corrosion-resistant protective paint.

[0027] The application provides a power system for an explosion-proof trolley, and effectively solves the problems of low-temperature charging difficulty, short endurance time, poor battery pack data collection and equalization management effect, and improper control strategy of the existing trolley, and achieves advanced reliability, controllable risk, and long service life. BRIEF DESCRIPTION OF DRAWINGS

[0028] Figure 1 A block diagram of the power system for the explosion-proof trolley of the application is shown in the figure.

[0029] Figure 2 A whole schematic diagram of the central control explosion-proof box of the application is shown in the figure.

[0030] Figure 3 An explosion view of the central control explosion-proof box of the application is shown in the figure.

[0031] Figure 4 A BMS block diagram of the application is shown in the figure.

[0032] Figure 5 A BMS software block diagram of the application is shown in the figure.

[0033] Figure 6 A BMS signal connection diagram of the application is shown in the figure. DETAILED DESCRIPTION

[0034] In order to make the purpose, content and advantages of the application more clear, the specific embodiments of the application are further described in detail below with reference to the drawings and examples.

[0035] The application optimizes the design of the environmental adaptability, electromagnetic compatibility adaptability and power adaptability of the equipment in the military special environment, and realizes advanced reliability and long service life.

[0036] The whole vehicle power system includes one set of central control explosion-proof box, two sets of battery heating modules, one set of DC220V direct current power supply, two sets of explosion-proof battery packs, one set of explosion-proof motor driver, one set of explosion-proof display, one set of charger, explosion-proof filler and wire harness, as shown in the figure. Figure 1

[0037] Among them,

[0038] ​The central control explosion-proof box adopts HWBMS-001, is connected with a battery heating module, a DC 220V direct current power supply, an explosion-proof battery pack, an explosion-proof motor driver, an explosion-proof display and a charging machine, and is used for completing functions of battery pack state monitoring, up and down electric action decision execution, system self-checking and the like;

[0039] The battery heating module adopts DC 220V power supply, is connected with the explosion-proof battery pack, and is used for heating the battery;

[0040] The explosion-proof battery pack comprises a first battery pack and a second battery pack, each battery pack adopts a mode that 16 battery cores are connected in series, and is used for providing power for the carrier;

[0041] The input voltage of the motor driver is DC 36-48V, and the maximum current is 150A;

[0042] The explosion-proof display adopts a DC 12V power supply interface and an RS485 communication interface;

[0043] The charging machine is used for charging the explosion-proof battery pack, input AC 220V, and output DC 48V.

[0044] The power system of the application is designed as follows:

[0045] Power supply function: power supply is provided for a two-way motor, a battery pack management system explosion-proof wiring box, a display and the like through the first battery pack.

[0046] Battery pack management system function:

[0047] Discharge management: overvoltage, undervoltage, overcurrent, short circuit and overtemperature protection are provided during the discharge of the battery pack, and the battery packs can be automatically switched;

[0048] Charging management: function management is realized during the charging of the battery pack, and the charging gun state is automatically detected, charging protection and voltage equalization functions are provided;

[0049] Monitoring display: parameters such as battery pack bus voltage, bus current, single battery voltage, single battery temperature, environmental temperature, battery pack and vehicle body insulation resistance are detected in real time, and are displayed through the explosion-proof display;

[0050] Battery residual capacity estimation: the residual capacity of the battery is estimated in real time through parameters such as single battery voltage, current and single battery temperature;

[0051] Battery monitoring state evaluation: the battery monitoring state is evaluated in real time through parameters such as single battery voltage, current and single battery temperature;

[0052] Fault diagnosis alarm and automatic protection: battery fault diagnosis, alarm and automatic protection functions are provided;

[0053] System self-checking: self-checking is realized after the system is powered on;

[0054] Data record storage: support running data, fault data, historical event data record, store events for no less than 6 months;

[0055] Emergency return home: in the case that the vehicle cannot be started due to low battery level, the emergency return home switch can be actuated to forcibly start the vehicle.

[0056] Battery system function: when the ambient temperature is low, the user can turn on the heating film switch to heat the battery pack through the heating film.

[0057] The working process of the power system is as follows:

[0058] S1, the system is powered on by rotating the knob switch on the carrier, and if the power-on is normal, the display power indicator light is green;

[0059] S2, after the system is normally powered on, the system performs self-checking of the vehicle state parameters, and after the self-checking is completed, the display shows the state information of the battery pack;

[0060] S3, rotate the motor start / stop button, the motor power supply is normal, and the forward / reverse and speed control are performed through the vehicle body manual lever, and the display real-time checks the battery pack state parameters;

[0061] S4, insert the charging gun, the main display shows the battery pack charging state, the system defaults the first battery pack to be charged first, the display shows that the first battery pack is in the charging state, and when the battery power reaches the preset state, the system automatically switches to the second battery pack for charging;

[0062] S5, remove the charging gun, the system defaults the second battery pack to be discharged first, the display shows that the second battery pack is in the discharging state, and when the battery power reaches the preset state, it is switched to the first battery pack for discharging;

[0063] S6, when both battery packs are in the loss point state, the discharge contactors are in the open state, the emergency return home knob switch on the carrier is rotated, the system forcibly closes the battery pack to supply power to the motor controller, and the main display shows the battery health state serious warning information.

[0064] Central control explosion-proof box design

[0065] The central control explosion-proof box includes a box body, a BMS, a DC 12V power supply, a Hall current sensor, a contactor, a relay and a power resistor. The BMS is composed of one battery master unit BCU and two battery front-end acquisition and management units BMU. The central control explosion-proof box has a bus voltage input / output interface, a cell temperature and voltage acquisition interface, a display communication interface and a load power supply interface.

[0066] The box body and the box cover of the central control explosion-proof box are respectively welded from 12mm and 8mm low-alloy steel plates (Q345C), and the box body and the box cover are tightly connected by bolts. The inlet and outlet lines of the central control explosion-proof box adopt explosion-proof packing boxes, which are installed on the left and right sides of the box body. The left and right sides of the box body are provided with mounting holes at the bottom, facilitating the installation of the device and the support. The device nameplate is placed on the box cover and is made of brass. The overall length, width and thickness of the box body are 392*212*160mm, as shown in Figure 2

[0067] As shown in Figure 3 , the DC12V direct current power supply and the BCU are installed in the box body, and the BMU is installed on the side of the box body. The BMS design of the central control explosion-proof box includes BCU design, BMU design and DC power supply design. The BMU collects the battery temperature and voltage facing the front-end battery unit, the BCU controls the whole vehicle charging and discharging process as the decision layer and the execution layer, and the DC power supply is used to power the BMS.

[0068] As shown in Figure 4 , the system adopts a two-level distributed hardware platform architecture, and the BMS includes one BCU mainboard and two BMU slave boards. BMU1 corresponds to the first battery pack, and BMU2 corresponds to the second battery pack. The BMU completes the voltage and temperature detection of the single battery in the corresponding battery pack, calculates the SOC and SOH, and reports the detection and calculation data to the BCU through the internal communication bus. The BCU detects external emergency open home and other passive signals, evaluates the system working condition according to the detection results and the battery temperature and voltage data uploaded by the BMU, and performs comprehensive management, scheduling and charging and discharging management. The BCU selects STM32F105RBT6 of ST company. The main control chip of the BMU selects MPC5744P digital signal processing chip of NXP company.

[0069] SOC calculation needs to model the battery by an electrochemical model, and establish a physical and electrical model of the internal structure of the simulation battery pack. According to the physical principles of solid matter conservation and charge conservation, electrolyte liquid matter conservation and charge conservation, electrode reaction kinetics, etc., the partial differential equations of the battery state are constructed, the equations are solved, and the equation set is solved by using the non-polar Kalman filtering algorithm. Finally, the lithium ion concentration in the positive and negative solid phases and the electrolyte liquid phase is obtained, which is the SOC. In actual application process, during SOC calculation, the SOC is calculated according to the highest and lowest power cells in the current battery pack, and the SOC of the whole pack is obtained after comprehensive averaging.

[0070] ​In SOH calculation, based on the battery data collected by the BMU in real time, the parameter sensitivity of the aging parameters affecting the battery performance is analyzed in combination with the battery electrochemical model, the capacity and health state information of the battery are obtained through the electrochemical aging parameters, i.e. SOH. In actual application, the SOH calculation needs to comprehensively consider the sensitivity of each parameter to the battery aging.

[0071] As shown in Figure 5 , 6 , the BMS software includes BMU software, BCU software and display software. The BMU software includes data acquisition, state evaluation, balance management, charger state detection, fault handling, self-checking, data interaction and the like, the BCU software includes peripheral control, self-checking, data storage, data processing, alarm fault determination, data interaction and the like, and the display software includes a battery pack information display interface, a system self-checking display interface and a fault display interface.

[0072] The BCU control software connects the BMU1 software and the BMU2 software through CAN and connects the display software through RS485. The BMU1 software obtains the first battery pack bus voltage, current, first battery pack single cell voltage, temperature and charger signal, and the BMU2 software obtains the second battery pack bus voltage, current, second battery pack single cell voltage, temperature and charger signal.

[0073] The system of the present application adopts aluminum material for full welding of the cabinet body, performs three-proofing treatment on the printed parts, performs potting treatment on the connector wiring end, and is designed as a whole for sealing to prevent water vapor and salt mist from entering the box.

[0074] The present application adopts high-strength metal material, and the structural design avoids stress concentration to resist the impact force transmitted by the ship body structure.

[0075] The present application coats the outer surface of the cabinet with corrosion-resistant protective paint and selects a pin-type internal connector to meet the vibration and impact requirements.

[0076] The present application effectively solves the problems of low-temperature charging difficulty, short endurance time, poor battery pack data acquisition and balance management effect, and improper control strategy of the existing trolley, and achieves advanced reliability, controllable risk and long service life.

[0077] The above only describes the preferred embodiments of the present application, and it should be noted that for those skilled in the art, without departing from the technical principles of the present application, a number of improvements and modifications can be made, and these improvements and modifications should also be considered as the protection scope of the present application.

Claims

1. A power system for an explosion-proof truck, characterized in that, The system comprises a central control explosion-proof box, a battery heating module, a 220V DC power supply, an explosion-proof battery pack, an explosion-proof motor driver, an explosion-proof display and a charger; The central control explosion-proof box is connected with the battery heating module, the 220V DC power supply, the explosion-proof battery pack, the explosion-proof motor driver, the explosion-proof display and the charger, and is used for completing battery pack state monitoring, up and down power action decision execution and system self-checking; The battery heating module is powered by DC 220V, is connected with the explosion-proof battery pack, and is used for heating the battery; The explosion-proof battery pack comprises a first battery pack and a second battery pack, each battery pack adopts a 16-cell series connection mode, and is used for providing power for the carrier. The input voltage of the motor driver is DC 36-48V, and the maximum current is 150A, and the motor driver is used for driving the motor. The explosion-proof display adopts a DC 12V power supply interface and an RS485 communication interface. The charger is used for charging the explosion-proof battery pack, and the input is AC 220V and the output is DC 48V. The working process of the system comprises the following steps: S1, the system is powered on by rotating a knob switch on the carrier, if the power-on is normal, the display power supply indicator light is green; S2, after the system is normally powered on, the system performs whole vehicle state parameter self-checking, after the self-checking is completed, the display displays the state information of the battery pack; S3, the motor start / stop button is rotated, the motor power supply is normal, the forward / rearward and speed control are performed through the vehicle body manual lever, and the display is used for checking the battery pack state parameters in real time; S4, the charging gun is inserted, the main display displays the battery pack charging state, the system defaults the first battery pack to be preferentially charged, the display shows that the first battery pack is in the charging state, when the battery capacity reaches a preset state, the system automatically switches to the second battery pack for charging; S5, the charging gun is pulled out, the system defaults the second battery pack to be preferentially discharged, the display shows that the second battery pack is in the discharging state, when the battery capacity reaches a preset state, the system switches to the first battery pack for discharging; S6, when the two battery packs are in the loss point state, the discharge contactors are in the open state, the emergency home knob switch on the carrier is rotated, the system forcibly closes the battery pack to supply power to the motor controller, and the main display displays the battery health state serious warning information.

2. A power system for an explosion-proof truck as defined in claim 1, characterized in that The central control explosion-proof box comprises a box body, a BMS, a 12V DC power supply, a Hall current sensor, a contactor, a relay and a power resistor, and has a bus voltage input / output interface, a cell temperature voltage acquisition interface, a display communication interface and a load power supply interface.

3. A power system for an explosion-proof truck as defined in claim 2, characterized in that The box body and the cover of the central control explosion-proof box are respectively formed by welding low alloy steel plates with thicknesses of 12 mm and 8 mm, and are tightly connected through bolts; the central control explosion-proof box uses an explosion-proof packing gland, the packing gland is installed on the left and right sides of the box body, and the left and right side box bodies are provided with mounting hole positions at the bottom, so that the equipment and the support are conveniently installed; the equipment nameplate is arranged on the cover and is made of brass.

4. The power system for an explosion-proof cart of claim 2, wherein, The BMS comprises one battery master unit BCU and two battery front end acquisition and management units BMU1 and BMU2, the 12V DC power supply and the BCU are installed in the box body, and the BMU is installed on the side of the box body.

5. A power system for an explosion-proof truck as defined in claim 4, characterized in that BMU1 corresponds to the first battery pack, BMU2 corresponds to the second battery pack, BMU completes the voltage and temperature detection of the single battery in the respective corresponding battery pack, SOC and SOH calculation, and reports the detection and calculation data to BCU through the internal communication bus, BCU detects the external emergency return home signal, and according to the detection results and the battery temperature and voltage data uploaded by BMU, the system working condition is evaluated, and comprehensive management, scheduling and charge-discharge management are performed.

6. A power system for an explosion-proof truck as defined in claim 5, characterized in that The BCU selects STM32F105RBT6 of ST Company, and the main control chip of the BMU selects MPC5744P digital signal processing chip of NXP Company.

7. A power system for an explosion-proof cart as defined in claim 5, wherein, In the SOH calculation, based on the real-time battery data collected by the BMU, the parameter sensitivity analysis of the aging parameters affecting the battery performance is performed combined with the battery electrochemical model, the capacity and health status information of the battery are obtained through these electrochemical aging parameters, that is, SOH.

8. The power system for an explosion-proof cart of claim 5, wherein, The BMS software includes BMU software, BCU software and display software; the BMU software includes data acquisition, state evaluation, equalization management, charger state detection, fault handling, self-checking, data interaction software, the BCU software includes peripheral control, self-checking, data storage, data processing, alarm fault determination, data interaction software, the display software includes battery pack information display interface, system self-checking display interface and fault display interface; the BCU control software connects the BMU1 software and the BMU2 software through CAN, and connects the display software through RS485; the BMU1 software obtains the first battery pack bus voltage, current, first battery pack single voltage, temperature and charger signal, and the BMU2 software obtains the second battery pack bus voltage, current, second battery pack single voltage, temperature and charger signal.

9. A power system for an explosion-proof cart as defined in claim 1, wherein, The box body of the central control explosion-proof box is fully welded with aluminum material, the printed parts are treated with three-proofing, the connector wiring end is filled and sealed, and the whole is designed as a sealed design to prevent water vapor and salt mist from entering the box; High-strength metal materials are used, and stress concentration is avoided in the structural design to resist the impact force transmitted by the ship structure; The outer surface of the case is coated with corrosion-resistant protective paint.

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